TABLE OF CONTENTS. Page Introduction... General Information Maintenance & Repair

Transcription

1 TABLE OF CONTENTS Page Introduction... General Information... 2 Maintenance & Repair Top Running Rotating Axle Wheel Assembly Removal... 7 Top Running Rotating Axle Wheel Assembly Installation... 9 Identifying Your Product... Parts Lists Identification Rotating Axle End Truck: 6" & above... 4 Brake Motor General Information... 6 Leeson Motor... 7 DINGS Brake: 50 Series Series STEARNS Brake: 56,000 Series Drive Assemblies Benzlers Drives:BTM Series... 4 SEW Eurodrive ACE Drive: ASM ACE Drive: MTV Jacksboro Hwy. Ft. Worth, Texas 7635 Phone: Fax: Visit our WEBSITE:

2 INTRODUCTION GENERAL INFORMATION: This manual provides information on the Ace World Companies products as well as furnishes service and parts information. The information contained in this manual at time of publishing is correct to the best knowledge of Ace World Companies. While every effort has been made to furnish correct and accurate, as well as sufficient information for maintenance, service and parts, this manual and information contained herein is subject to change without notice. Any questions regarding the information in this manual should be directed to Ace World Companies, Fort Worth. Ace World Companies and any and all associated companies can not be held liable for lack of or unintended omissions or errors in this publication or improper safety precautions and/or user training when performing maintenance or repair on Ace World Companies products. WARRANTY: This warranty that accompanies the Ace World Companies products is listed on the back cover of this manual. This warranty is void if Ace World Companies products are used under or with any of the following conditions: Loadings exceeding maximum rated loadings listed in Ace World Companies product catalogs. Accessories or other equipment not designed or approved by Ace World Companies. Modifications which effect the mechanical and structural integrity of the Ace World Companies products. Unsafe operation and/or inexperienced maintenance personnel. NOTE: There is no substitution for experience. Ace World Companies employs trained and experienced design and maintenance personnel ready to help you 24 hours a day. If you have any questions concerning any information contained herein or with Ace World Companies products in general, please call the number on the front cover of this manual.

3 GENERAL INFORMATION INSTALLATION: There are many different ways to install or mount the bridge girders to the endtrucks. Since each crane builder or user has their own preference Ace World Companies does not suggest or offer in this manual information on how to mount the bridge girders to the endtrucks. However, Ace World Companies has many experienced engineers in the design of overhead bridge cranes and can offer assistance or ideas on designing the girder/endtruck connection. SHIPMENT/RECEIVING: Ace World Companies products are sold F.O.B. factory and freight expenses are the responsibility of the purchaser. Ace World Companies products can be shipped by most common carriers. While Ace World Companies attempts to package the product sufficiently for transportation, damage during transit may and more often than desired, does occur. The responsibility for filing a damage claim against the freight company lies with the purchaser. If damage does occur, contact Ace World Companies immediately so we can ship replacement parts and/or help in the repair determination. STORAGE: Ace World Companies products are shipped ready for immediate use. If the need arises, Ace World Companies products should be stored indoors in a clean, dry atmosphere. The product should be blocked off the floor, away from moisture and covered loosely with a heavy plastic tarp to prevent dust and dirt from accumulating on the equipment. Any bare metal surfaces such as open gears, shafts, axles, wheel treads etc. should be coated with a rust preventing compound. If storage is for an extended period of time, it is also recommended to periodically rotate the wheels manually to insure grease does not settle in the bearings and oil in the gear reducer coats the gears. PAINTING: Ace World Companies products are supplied hand cleaned and prime painted with a universal primer, ready for finish coating by the purchaser. Special surface preparation and paint can be supplied if required by purchaser. When finish painting Ace World Companies products it is recommended to follow the paint manufacturers instructions as well as carefully mask wheel treads, bumpers and open motor housings. Remember to remove any masking material prior to putting the product into operation. 2

4 MAINTENANCE AND REPAIR ALL MAINTENANCE AND REPAIR SHOULD BE IN ACCORDANCE WITH ANSI B30 SPECIFICATION This section provides information on the maintenance and repairs for all of the Ace World Companies products. This section deals with lubrication, inspection, disassembly and assembly of the products. It is not intended to provide guidance for all situations but deals with everyday, normal maintenance items. MAINTENANCE: The following information provides guidelines for periodic inspections of Ace World Companies products. It is suggested each user develop their own periodic maintenance schedules consistent with the intended usage of the Ace World Companies product. Periodic inspection of the endtruck and trolley assemblies is suggested to insure proper operation and lubrication. The frequency of the inspections depends on the operating environment. Inspections should include the following but not be limited to: ) Check for loose or missing bolts and repair or replace at once. 2) Inspect the wheel flanges and rail for abnormal wear. The wheels are designed to contact the rail head. This is normal. Depending on the operation of the crane and how well the crane was built and squared, the wheels should give years of good service. 3) Inspect the wheels for flat spots or any unusual wear patterns or markings. 4) Inspect the bumper and rail sweeps for cracked bumpers or bent rail sweeps. Fix or replace at once. 5) Inspect the drive pinions on under running and fixed axle trucks for lubrication, wear and alignment with the wheel gear. 6) Inspect the wheel for excessive float. The wheels are designed to give adequate clearance between the wheel flanges and the rail head. CMAA specifications contain guidelines for the amount of float a wheel should have on the rail. Under running endtrucks should have between.25 inch to.25 inch float between the wheel flange and runway beam while top running endtrucks should have minimum.75 inch float up to.5 inch float depending on the wheel size and crane span. 3

5 MAINTENANCE AND REPAIR 7) Inspect the drive assembly for leaking oil and excessive noise. Inspect the drive mounting torque arm bolts and bushings for proper operation. Inspect the brake torque and brake disc gap. Refer to the applicable drive assembly in the end section of this manual for more information. If any of the above conditions exist, fix or replace them or contact Ace World Companies for guidance. LUBRICATION: Lubrication of Ace World Companies products is the most important maintenance item. Lubrication should be performed periodically with the frequency dependent upon the operating environment. However, at a minimum it is suggested complete lubrication be accomplished every three months. The under running endtrucks require lubrication of the exposed drive pinion and wheel gear. If lubrication is required, it is suggested to completely clean the pinions and gears first with a solvent to remove all the old grease. Inspect the gears for wear and replace if required. Regrease with a spray on or brush on inherent open gear lubricant such as "DEM - KOTE" Gear and Wire Rope Lubricant (AGMA Grade 0 as mimimum), which is available from Ace World Companies or through your Grainger or similar industrial supply catalog. No greasing of the wheel bearings is required since they are lifetime lubricated and sealed. Refer to the appropriate drive section at the end of this manual for lubrication requirements for the gear reducers and motors. The top running fixed axle endtrucks require similar lubrication of the exposed drive pinion and wheel gear as the above under running endtrucks. The top of the endtruck has an inspection hole directly above the pinion/gear mesh line. If lubrication is required, it is suggested to completely clean the pinion and wheel gear first with a solvent to remove all the old grease. Inspect the gears for wear and and replace if required. Regrease with a spray on or brush on inherent open gear lubricant such as "DEM - KOTE" Gear and Wire Rope Lubricant, which is available from Ace World Companies or through your Grainger or similar industrial supply catalog. No greasing of the wheel bearings is required since they are lifetime lubricated and sealed. Refer to the appropriate drive section at the end of this manual for lubrication requirements for the gear reducers and motors. 4

6 MAINTENANCE AND REPAIR The top running rotating axle endtrucks and top running double girder package trolleys both have similar lubrication requirements. The only lubrication required is periodic greasing of the spherical roller bearings. Each bearing has a grease Zenk on the bearing capsule. The bearings are factory greased but will require periodic greasing. Use a high grade bearing grease such as EP-2 applied with an industrial grease gun to the bearing capsule Zenk fitting. Use manufacturer recommended standard lubricant based on ambient working temperature. Two or three good pumps should normally be enough. Do not pump so much grease into the bearing that it begins to push out around the bearing seal. This will cause failure of the seal and also possibly get grease on the rail head which will cause traction problems for the wheel. Refer to the appropriate drive section at the end of this manual for lubrication requirements for the gear reducers and motors. BOLTS AND HARDWARE: Ace World Companies does not include bolts and hardware as spare parts. It is assumed user can locate and apply the proper hardware. However, as a guideline, Ace World Companies uses domestic grade 5 hardware as a minimum in all its products. Any hardware provided by user should be grade 5 or better. Below is a sample of identification on the bolt heads and torque values to tighten bolts. Size Torque Foot-Lbs. Dry Lub. 8 mm /2-3 UNC 5/8 - UNC 3/4-0 UNC The above torque specifications chart is based on S.A.E. bolt steel classifications. The torque values vary for dry or lubricated threads. The term lubricated includes the application of thread lubricants, lubrizing, cadmium plating and the use of hardened washers. All Ace World Companies hardware is installed with split or lock washers. 5

7 MAINTENANCE AND REPAIR REPAIR: Repair of Ace World Companies products is primarily limited to replacement of the worn or damaged parts. These parts include items such as wheel assemblies and drive assemblies. If structural damage occurs to the frame of the endtruck, most likely the entire endtruck will need to be replaced. This manual does not include information on determining whether this is necessary or on how to remove and replace the existing endtruck frame. Contact Ace World Companies for information and guidance on removing the endtruck. Refer to the appropriate drive section at the end of this manual for guidance on damage and/or repair to the drive assemblies. 6

8 TOP RUNNING ROTATING AXLE ENDTRUCKS WHEEL ASSEMBLY REMOVAL The wheel assemblies can be removed while the crane is on the runway. To accomplish removal of either the drive wheel assembly or an idler wheel assembly, follow the steps below:. Move the empty trolley hoist to the opposite end of the bridge. WARNING! Disconnect and lock out the power source feeding the crane mainline or other power source. Injury or death to personnel will result if this precaution is not followed. 2. Block the crane from moving on the runway by placing wheel chocks in front of the wheels opposite the side of the crane the wheel assembly is being removed. Do not rely on the drive brake assembly to hold the crane in position. 3. If a drive wheel assembly is being removed, first remove the drive assembly by remov- ing the bolt at the end of the drive axle. Then remove the bolt which secures the drive to the torque arm. Be careful at this point, the drive will rotate freely on the drive axle. If drive assembly is flange mounted, remove the four bolts holding the drive to the bear- ing capsule. If the drive is an Ace Drive unit, refer to the end section of this manual for instructions on removing the KIBO bushing. With all the mounting bolts removed, carefully slide the drive off the drive axle and support securely on the walkway or other means. If no means is available to support the drive after it is removed from the axle, first dis- connect the wires to the drive, remove the mounting bolts and lower drive to the ground. 4. Remove the rail sweep and bumper assembly. 5. Remove the bolts holding the bearing capsules to the truck frame. 6. Using a suitable jack, placed behind the wheel and not in front of the wheel, jack up the endtruck frame enough so the bearing capsule will clear the truck frame as the wheel assembly is rolled out the front of the truck. This may be as much as three inches. NOTE These are suggested practices. 7

9 TOP RUNNING ROTATING AXLE ENDTRUCKS WARNING! The wheel assembly is extremely heavy. Caution must be observed that nothing falls to the ground or other personnel are not under the location where the wheel assembly is being removed. 7. Carefully roll the wheel assembly out of the truck frame. Once the wheel assembly clears the truck frame, attach a suitable sling or other rigging and lower assembly to the ground. **CAUTION** BEARING CAPSULES ARE A SLIP FIT AND MAY FALL. REMOVAL OF CAPSULES MAY BE NEEDED. Repair of the wheel assemblies is limited to replacement of the components. Inspect the wheel running surface for wear. If bearings need to be replaced, they must be replaced in pairs. The bearings are slip fit into the bearing capsule and light press fit on to the axle. Be careful when removing the bearings to not damage the bearing seal between the bearing and the axle shoulder. While the unit is disassembled, it is a good idea to clean all the components of the old grease and regrease. Installation of the rotating axle wheel assemblies follows the reverse of the removal outlined above. WARNING! Be sure the crane power source is still locked out. Failure to insure this will result in injury or death to personnel. 8

10 TOP RUNNING ROTATING AXLE ENDTRUCKS WHEEL ASSEMBLY INSTALLATION ) Clean all components. Install the axle into the wheel by heating the wheel bore and pressing the axle into the wheel with a large hydraulic press. Press axle into the wheel all the way up to the shoulder of the axle. 2) Install bearing grease seal onto the axle and locate all the way up to the shoulder. 3) Heat the bearing in a bearing heater and install on the axle all the way up to the seal and shoulder. Follow good bearing installation procedures to prevent damage to the bearing that will lead to premature failure. 4) After the bearing has cooled, install the bearing capsules onto the bearings, tapping lightly around the circumference with a wooded mallet. Insure the bearing is fully seated into the capsule. 5) With the truck frame still jacked up, position the assembled wheel assembly on the rail in front of the endtruck frame. Carefully roll the wheel assembly into the truck frame so the bearing capsules are centered on the frame boxes. WARNING! The wheel assembly is extremely heavy. Caution must be observed that nothing falls to the ground or other personnel are not under the location where the wheel assembly is being removed. 6) While keeping the bearing capsules centered on the bores, carefully lower the truck frame down onto the capsules. It is critical that the capsules seat properly and com- pletely into the frame bores. Be sure the bolt holes in the capsules line up with the tapped holes in the truck frame before allowing the weight of the crane onto the capsules. 7) Reinstall the bearing capsule bolts and tighten. 8) Reinstall the rail sweep and bumper assembly. 9) If the bearings were not greased prior to assembly with the truck frame, grease the bearings with several good pumps from a grease gun. 9

11 TOP RUNNING ROTATING AXLE ENDTRUCKS 0)Reinstall the drive assembly. Check the drive assembly key in the axle. Clean the bore and install the drive on the drive axle. Refer to the end section of this manual for instruct- ions on installing the drive assembly depending on the type drive used. )Install all the drive assembly bolts. Reconnect the motor wires if wires were disconnected. Be careful, the drive assembly is heavy and it will rotate freely on the drive axle until the torque arm bolt is attached or the flange bolts are installed. 2) Recheck all bolts for tightness. Remove the wheel chocks. 3)Restore power to the crane and test operation fully before lifting a load or putting crane back into operation. 0

12 END TRUCK STYLE IDENTIFICATION IDENTIFYING YOUR PRODUCTS: It is important to identify the Ace World Companies products to insure you get the correct parts or information you need to service them. The most important item of identification is the Ace World Companies serial number or job number. This number is located on the front of this manual as well as being stamped on the Ace name plate located on the equipment as well as being hard stamped into the truck or trolley frame near the drive assembly location.

13 END TRUCK STYLE IDENTIFICATION IDENTIFYING YOUR PRODUCTS: The Ace World Companies model number can be used to identify the style of Ace World Companies product you have. This number can be found on the engraved tag riveted to the product or on the front cover of this manual. Below are drawings of each style of product and an example model number. Rotating Axle Example: R0TD25090 Fixed Axle Under Running Example: F08USB

14 ,, "", I I!, I I I I I,f=$ I 'I I i ~ ~ -II TIl = Top Running Tro lley Frome Example: TRS003S075- Fixed Axle Top Running -~ I,... ~.. " I I/~ "':\ : \, I' ~ 'I I' I., Example: 0BTPW0608 3

15 2 0IDLER VlHEEL G)DRIVE VlHEEL ROTATING AXLE END TRUCK TOP RUNNING 6" AND UP

16 Rotating Axle End Truck Top Running 6 Wheel & Up Parts List Frame, Top Running End Truck 2 Idler Wheel Assembly 5 Capsule, closed 7 Bearing, roller 8 Seal Idler, wheel 2 Axle, Idler 2 Zert fitting, straight 23 Bolt 24 Nut, heavy hex 3 Drive Wheel Assembly 4 Capsule, open 5 Capsule, closed 6 Drive, wheel 7 Bearing, rollar 8 Seal 9 Axle, Drive 0 Key 2 Zert fitting, straight 22 Zert fitting, Bolt 24 Nut, heavy hex 3 Brake 4 Motor 5 Gearbox 6 Bumper 7 Rail sweep 25 Bolt 26 Nut, heavy hex 8 Girder plate top 9 Girder plate side 30 Bolt (girder plate mounting) 3 Washer, lock (girder plate mounting) 32 Washer, load indicating (girder plate mounting) 33 Nut, heavy hex (girder plate mounting) 20 Torque arm 24 Bolt 25 Washer, lock 26 Bolt (gearbox mount) 27 Washer (gearbox mount) 28 Washer, lock (gearbox mount) 29 Nut, heavy hex (gearbox mount) 5

17 SECTION BRAKE MOTOR 6 - DRIVE INFORMATION ASSEMBLIES Ace motors are three phase totally enclosed motors incorporating an electromagnetic spring-set disc brake. Motor load is stopped automatically when power is turned off, ensuring a precise stop and quick braking action. Brake activation is obtained without axial sliding of the shaft and is specifically engineered to provide years of worry free performance. Ace brake motors have been designed to be used with lifting and translating machinery. The integral brake design utilizes an asbestos free brake disc, with a high coefficient of friction. All Ace brake motors have a power-off manual release for convenience and use in the case of power loss. Ace brake motors incorporate either a NEMA or IEC Design B, totally enclosed motor platform, utilizing a Class H insulation system (inverter rated), providing superior motor protection against voltage spikes induced by variable frequency drives. Motors are available from stock in both 4 pole (800 RPM) and 6 pole (200 RPM) designs, and are available from 3/4 HP thru 0 HP. All Ace brake motors have Klixon style motor protectors, and can be modified (upon request) to meet specific environmental requirements. U.L., CSA, ISO Standards and Approvals. Underwrites Laboratories, Inc.. U.L recognized Class H insulation system. File #E55555, Guide Number OBJY2. 2. U.L. recognized protector winding combinations. File #E Guide Number XEWWR2. Canadian Standards Association. CSA Report Number L33543, Guide Number CSA Report Number LR6204. ISO Quality Certification Design and Manufacturing Facility, ISO 900, Certificate Number RvC # EN2900, BS5750: Part I and ANSI/ASQC Q9-9 ISO9002 Certificate Number RvC #

18 2 3 NOTE: ITEMS,2,&3 ARE FOR IEC MOTORS ONLY AND ARE NOT INTERCHANGEABLE WITH ITEM 9 '~!.~~ ~~ -~ MOTOR EXPLODED VIEW

19 VIEW FROM OUTSIDE OF MOTOR AT SWITCH END. LINE LEADS I ~ PI I TSTAT(S) I P2 BRAKE -",,".. " n.. ~ T2.... T3.. T4.. T5 T6 T7, : T5.. I T8 T6.. I I T4 T9 SEE TABLE FOR BRAKE CONNECll0NS T9 T3 T8 T2 8 Tl T7 STERNS BRAKE DINGS BRAKE VOLTAGE Ll L2 JOIN Ll L2 JOIN 3 (BLACK) (YELLOW) HIGH (RED) 2 (RED) 4 iblacki 2 (BLACK) ~ (YELLOW] 3 (BLACK' (RED) 2 (RED) 2 (BLACK) (YELLOW) LOW (BLACK) 4 (BLACK' 3 iblack' 4. iyellow IlI.lRANCES UNlESS OlHERWISE SPEaFlm VOLTAGE L L2 L3 JOIN &: INSULATE (T4,T7) HIGH n T2 T3 (TS,T8) (TS,T9) LOW n,t7 T2,T8 T3,T9 T4,TS,TS LEESON ELECTRIC CORPORATION DECIMALS.00 '".0 DRAWN ROW 0 4 LE EXTERNAL ~~ING DIAGRAM. 000 '".000 """K'D 3 PHASE W 0 PROTECTOR.0000 '".0000 _"- MAn.. DECAL NO. IIE\ISIOII BY DAlE FRACIOIIS ""/84 SCALE,- DECAL lhll DRA.NG.. ~ AND DETAL IS OI.IR PRCRRY ANGLES '" /2" REF. OODOIo-5 FISH I SIZE DRAIIINO NO. AND MUST NOT USED EXCEPT II CQrlrETlCIN... OUR WCIRIC CAMFAB INC. I A ALL lights OF DESIGN AND IN\tENION ARE RESER'IED.. ""/M FM.

20 "D_, DYNAMICS GROUP Bulletin No. BK468A (5/03) 50 Series Enclosed Brake Instructions Ace World Company Enclosed Housing Inertia Wt. Lbs. Rotating Model Torque Parts Lb. Ft. Net Pkg'd WK 2 in Lb. FF Table. List of Models Figure. 50 Series Brake IMPORTANT Read this bulletin carefully before installing or operating this brake. Failure to comply with these instructions cancels all warranties. WARNING Brake performance and features must be carefully matched to the requirements of the application. Consideration must be given to torque requirements, especially where an overhauling condition exists, as well as thermal capacity, ambient temperature, atmospheric explosion hazards, type of enclosure and any other unusual conditions. Improper selection and installation of a brake and/or lack of maintenance may cause brake failure which could result in damage to property and/or injury to personnel. If injury to personnel could be caused by brake failure, additional means must be provided to insure safety of personnel. Do not operate manual release or energize brake coil before installation, in order to preserve prealignment of rotating discs for ease of installation. Figure 2. Dimensions of Brake 4740 W. Electric Avenue.Aviwaukee, WI 5329 A4/ /FAX 44/ /Www. dingsco.com 9

21 Figure 5. Exploded View of Brake Table 2. Parts List ITEM PIECES NET WT. NO. REQ D PER PIECE DESCRIPTION PART NO. oz. RELEASE LEVER G oz. SPLINED HUB W/ SET SCREWS (SPECIFY BORE & KEYWAY) H oz. MACHINE SCREW, PAN HD. WITH LOCKWASHER W oz. COVER K oz. ANTI-BACKLASH SPRING G oz. PIVOT NUT G oz. LOCKNUT W oz. MAGNET ASSEMBLY (INCLUDES ITEM 23) Specify voltage & Hz. H oz. LOCKNUT W oz. RUBBER WASHER G oz. ROTATING DISC H oz. NUT, HEX W oz. TORQUE SPRING - BRONZE G oz. ARMATURE ASSEMBLY H oz. PRESSURE ARM ASSEMBLY H oz. STATIONARY DISC G oz. BRACKET ASSEMBLY K oz. RETURN SPRINGS G oz. COMPRESSION SPRING G oz. BRASS WASHER W oz. RUBBER SLEEVE G oz. SHADING COIL G

22 DESCRIPTION This brake is direct acting, electromagnetically released and spring set. It uses rotating and stationary disc contact to supply positive braking action. It retains quick release and setting capabilities at all times. Simplicity of design has reduced maintenance to an absolute minimum. As with any electromechanical equipment, however, periodic inspection and adjustment will assure optimum performance. As the friction disc wears, the magnet gap will increase. The magnet gap should be checked periodically and adjusted when necessary. INSTALLATION (See Figures 2, 3, 4 & 5) Before installing, refer to section on Torque Selection.. Remove hub (2) from brake and position on motor shaft with key per dimension shown in Figure 2. Stamped part number on hub should face away from motor. Tighten hub set screws to shaft with 6-8 lb. ft. torque. 2. Remove the three cover screws (3) and cover (4) and position brake over hub (2) on shaft. Bolt brake to motor flange with two /4 flat head screws. (NOTE: Be sure anti-rattle spring (5) does not rest in hub tooth space containing a set screw.) 3.Connect coil wire leads as indicated in Figure 3. Replace cover, three cover screws and rubber sleeve. Figure 4. Brake Gap Adjustment Figure 3. Wiring Diagram MANUAL RELEASE (See Figure 4) Manually release the brake by removing the rubber sleeve (2) and using a flat blade screwdriver to push the release lever () forward until it has moved approximately 25 o. The brake will remain in the released position as long as you hold the lever in this position. MAINTENANCE AND SERVICE FRICTION DISC REPLACEMENT (See Figure 4) When total wear on rotating discs () reaches /6, replace disc as follows:. Remove the rubber sleeve (2), three cover screws (3), cover (4), nuts (9), magnet assembly (8), washers (0), nuts (2), torque springs (3), armature (4), nut (7), nut (6), pressure arm (5) and stationary disc (6). 2. Install new rotating disc () making sure anti-rattle spring (5) is installed in position shown and does not rest in a hub tooth space containing a set screw. 3. Reassemble all parts in reverse order. NOTE: In reassembly, tighten nut (6) so that it just makes contact with pressure arm (5). LOCATE nut (2) /2 from end of stud as shown in Figure 4. Tighten nut (9) as described under MAGNET ASSEMBLY REPLACEMENT. Readjust magnet air gap as described under WEAR ADJUSTMENT. WEAR ADJUSTMENT (See Figure 4). As friction disc wears, magnet air gap A increases. When air gap A reaches.50 maximum, adjust to To adjust: Hold pivot nut (6), loosen lock nut (7), turn pivot nut (6) clockwise until air gap A measures.080 at center of magnet. (NOTE: Air gap should decrease slightly to measure When lock nut (7) is tightened against the pivot nut (6).) Hold pivot nut (6) and tighten lock nut (7) against it. Operate brake several times to see if ; air gap is maintained. If not, re-adjust following same procedure again. Any delay in adjusting air gap will result in a loss of torque and/or coil burn out. MAGNET ASSEMBLY REPLACEMENT (See Figure 4) Remove rubber sleeve (2), cover screws (3), cover (4), nuts (9) and magnet assembly (8). Replace magnet assembly. Be sure rubber pads (0) are under magnet bracket. TIghten nuts (9) to remove end play between nut and magnet bracket. TIghten with an additional /3 turn (two flats on nut). Check air gap as described under WEAR ADJUSTMENT and replace cover, cover screws and rubber sleeve. 2

23 BRAKE DOES NOT RELEASE Check for failure of power supply to brake. Check brake visually for broken or damaged parts. Check for broken leadwire or bad electrical connection. Check for correct voltage. Voltage must correspond to that listed on brake nameplate. If voltage is more than 0% below figure stamped on nameplate, magnet will not pull in, causing coil to burn out within minutes. If voltage is more than 0% above, coil will overheat and burn out. Check for burned out coils (coils may be charred or burned). BRAKE DOES NOT STOP Check brake visually for broken or damaged parts. Check disc wear (see WEAR ADJUSTMENT). Check for broken friction disc. Check hub. Be certain hub has not shifted position on shaft and rotating disc is fully engaged on hub. BRAKE CHATTERS OR HUMS Clean magnet faces if dirty. Insert a clean sheet of paper between the magnet faces and energize brake. Move paper around between faces to dislodge dirt. Finally, remove paper. Check if shading coil (23) is cracked, broken or out of position. Check for low voltage. Magnet will not pull in and coil will burn out if voltage is more than 0% below figure stamped on nameplate. MANUAL RELEASE DOES NOT WORK Check for broken or damaged parts. Check return springs (8). Replace if broken. Check magnet air gap A with lever in the normal position. Gap must be.060 at narrowest point. If gap is too small, motor shaft will not turn freely. Adjust to correct magnet gap as described under WEAR ADJUSTMENT. SPECIFICATIONS MOTOR FRAMES Frame HOUSING Steel DUTY Rated for continuous duty VOLTAGES All standard NEMA single phase voltages and frequencies available. Other voltages and frequencies are optional. MOUNTING Direct to NEMA C motor flanges. Brake is all position mounting. TORQUE lb. ft. ORDERING INFORMATION The following data should be furnished with your order for: REPLACEMENT PARTS Brake Model Number Part Number from Table 2 Part Description from Table 2 (On hub order furnish bore dia. & keyway dimensions) (On electrical parts specify voltage, phase & frequency) REPLACEMENT BRAKE Model Number Voltage, Phase & Frequency Hub Bore & Keyway Dimensions WARRANTY Seller warrants products manufactured by it and supplied hereunder to be free from defects in materials and workmanship under normal use and proper maintenance for a period of twelve months from date of shipment. If within such period any such products shall be proved to Seller s reasonable satisfaction to be defective, such products shall be repaired or replaced at Seller s option Seller s obligation and Buyer s exclusive remedy hereunder shall be limited to such repair and replacement and shall be conditioned upon Seller s receiving written notice of any alleged defect no later than 0 days after its discovery within the warranty period and, at Seller s option, the return of such products to Seller, f.o.b. its factory, when such return is feasible. Seller reserves the right to satisfy its warranty obligation in full by reimbursing Buyer for all payments it makes hereunder, and Buyer shall thereupon return the products to Seller. Seller shall have the right to remedy such defects. Seller makes no warranty with respect to wear or use items, such as belts, chains, sprockets, discs and coils, all which are sold strictly AS IS. The foregoing warranties are exclusive and in lieu of all other express and implied warranties (except of title) including but not limited to implied warranties of merchantability, fitness for a particular purpose, performance, or otherwise, and in no event shall the Seller be liable for claims (based upon breach of express or implied warranty, negligence, product liability, or otherwise) for any other damages, whether direct, immediate, incidental, foreseeable, consequential, or special. 22

24 Bulletin No. BK4655A (5/03) 60 Series End-Mount Brake Instructions Standard Housing Ace World Company Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference. DESCRIPTION These magnetic disc brakes mount directly onto NEMA 56C, 43TC, and 45TC frame motors, on the end opposite the drive shaft. The brake is direct acting, electro-magnetically released, and spring set. It uses rotating friction and stationary disc contact to supply positive braking action. It retains quick release and setting capabilities at all times. WARNING: Do not install or use these brakes in an explosive atmosphere. Figure * Inertia of Dimensions** Thermal Rotating Model Number of Torque Capacity Parts X G AC C N + /32 Number Rotating Discs Lb. Ft. HPS/MIN. Lb. Ft *Thermal capacity (HPS/MIN.) was determined under the following test conditions: a) Room temperature 72 o F. b) Stopping time of one second or less. c) Brake mounted in a horizontal position. d) Equal on and off times. e) 800 RPM f) Coil energized with 0% of rated voltage. **NOTE: Model A has an adaptor to mount to motor sizes 82TC through 25TC. All dimensions are measured from the face of the adaptor rather than the motor face. 23

25 Figure 5 Armature Replacement CAUTION: Load to be removed or blocked. Brake will be inoperative during this procedure. If you replace the magnet assembly, it may be necessary to replace the armature (5J). If it is badly deformed, it will be difficult to make the magnet quiet.. To replace, remove operator assembly (5) from brake. See Friction Disc Replacement Steps -3 on page 5. Remove nuts (5T), springs (5S) and carriage bolts (5R). This will allow the armature plate assembly to be removed from magnet bracket. 2. Remove screw (5Q), lockwasher (5P), locking plate (5N), two screws (5M), spacers (5L), and armature (5J). Inspect these parts and shock mount (5K). If worn, replace them also. 3. Put armature in place (ground side up) and install spacers (5L) and screws (5M). NOTE: See Fig. 5 Screws (5M) should be tightened to remove slack only. Then back off, counterclockwise on screw so that the next flat on screw is parallel with edge of the armature plate (5F). Install locking plate (5N), screw (5Q), and lockwasher (5P). Tighten screw with 30 lb. in. torque. 4. Reassemble to magnet bracket (5C) using items (5R), (5S) and (5T). Reassemble operator assembly to brake bracket. Set magnet air gap A and set torque springs (5S) to as shown in Fig. 3. Pivot Stud Adjustment CAUTION: Load to be removed or blocked. Brake will be inoperative during this procedure. This adjustment is made at the factory and may be required when replacing the magnet assembly (5A) or the armature (5J). The purpose is to regulate the height of the armature plate (5F) so that when the magnet (5A) is energized, the armature (5J) is parallel with it. This is required so that the magnet will be quiet. NOTE: Cover (20) must be removed to make this adjustment.. To adjust: Hold nut (9) which is adjacent to washer (8) and loosen the other nut (9) and remove it from the stud. 2. Energize the magnet and turn remaining nut (9) counterclockwise slowly until the magnet becomes noisy. Turn magnet on and off several times until you find the position where the magnet first becomes quiet. At this point, turn nut (9) /3 turn (two flats) in a clockwise position. Hold nut in this position and turn magnet on and off to make sure the magnet does not become noisy. 3. Holding this nut in place, screw on other nut and tighten it against the nut you are holding. Tighten firmly. 4. Operate the manual release. If the release does not operate properly, see Manual Release Adjustment on next page. 24

26 Manual Release Adjustment CAUTION: Load to be removed or blocked. Brake will be inoperative during this procedure. The manual release (3) may require adjustment after replacing the operator assembly 5), magnet (5A0, or armature (5J). It also may be required if adjustments are made on the pivot stud nuts (9). The release is working properly if: a) you turn release knob (3) clockwise to stop and the brake is released; b) the release knob returns to its normal position automatically when power is applied to the magnet. NOTE: Cover (20) must be removed to make this adjustment.. To adjust: Set air gap A as described under Wear Adjustment on page If the brake does not release, turn adjusting screw (5) counterclockwise /4 turn and try again. 3. If the release knob (3) does not return to its normal position automatically, turn screw (5) clockwise /4 turn and try again. NOTE: You may have to repeat Steps 2 or 3 to get the release to operate properly. It is important that the release knob returns to its normal position automatically when power is applied to the magnet. Manual Release Assembly Refer to Fig. 6. Place shaft of release knob (3) through hole in bracket (2). 2. Slide return spring (4) over shaft; straight leg of spring should enter shaft first with leg in the position shown. 3. Slip spring (6) over screw (5) and install in tapped hole in release shaft. Screw in until it stops. Make sure spring (4) is not caught under spring (6). 4. Engage bent end of spring (4) over spring (6) as shown. Pull it over with a needle-nose pliers or screwdriver. 5. Adjust release. See Manual Release Adjustment on the left. Figure 6 25

27 Figure 3 MAINTENANCE CAUTION: Before attempting to service or remove any components, make certain that the power is disconnected and that the load is completely removed, secured or blocked to prevent injury or property damage. Wear Adjustment 2. Measure air gap A using 3/8 to /2 wide feeler gauge. (Measure at center of magnet.) 3. Turn two square head adjusting screws (5H) until air gap A measures:.045/.050 for disc models.050/.055 for 2 disc models.060/.065 for 3 disc models Air gap should be the same on both sides. CAUTION: Load to be removed or blocked. Brake may be inoperative during this procedure. Before air gap A reaches.00, adjustment is required. Any delay in adjusting the magnet air gap will result in eventual loss of torque. Refer to Fig. 3.. To adjust, remove cover locknuts (22) and cover (20) to expose square head wear adjusting screws (5H) and expose magnet air gap A. 26

28 REPLACEMENT PARTS ILLUSTRATION r-~~- OP~F\ATOA ASSEMBLY 5 I NL~UOES I-SA Tl-I RU lit -~~----, ~ HiO 5P,sc L'iR i :!i' Ii EiJ - fil( 6t' ~ l:;;! 5M 50 l(;l lsi 27 ~L L!! 9-9 5F - tuneh NUT INOLUDED IN ITEM I!iF 5B - 5,, S H A~ I N I> Call.. INCLUDED IN ITEM 5A Figure 9

29 REPLACEMENT PARTS LIST Item No. Description Part Number Qty. Item No. Description Part Number Qty. Splined hub K06007-** 2 Bracket & 2 disc models (aluminum) L Bracket 3 disc model (aluminum) L Bracket 4 disc model (cast iron) L F Armature plate H G Nyliner bushing W H Wear adjustment screw, sq. hd. /4-20 x -/2 lg. W I Roll pin 5/32 dia. x 3/8 lg. W Release knob G Release return spring G Release adjustment screw W C 6 Release adjustment lock spring G Nameplate K J Armature lamination assembly G K Armature shock mount G L Armature spacer G M Hex hd. capscrew /4-20 x 5/8 lg. Grade 5 W E 2 5N Locking plate G Cap plug W Cover stud G Pivot stud W A Compression spring (all except 20 & 25 lb. ft.) G Compression spring (20 & 25 lb. ft.) G Stationary disc H * 3 Splined rotating friction disc H * 4 Stabilizer clip, rotating friction disc (when used) H * 5 Operator assembly: includes A through T K ** (not shown as an assembly) 5A Magnet assembly ** 5B Magnet shock mount G C Magnet mounting bracket H D Hex hd. capscrew /4-20 x /2 lg. W E 2 5E Armature plate assembly: includes F through Q H06054-** (not shown as an assembly) 5P Split spring lockwasher #8 W Q Soc. hd. capscrew #8-32 x /4 lg. W R Carriage bolt /4-20 G S Torque spring (blue).5 lb. ft. G S Torque spring (silver) 3 & 6 lb. ft. G S Torque spring (bronze) 0 & 5 lb. ft. G S Torque spring (green) 20 & 25 lb. ft. G T Locknut /4-20 W Hex hd. capscrew /4-20 x /2 lg. W E 2 7 Nylon bushing G Plain brass washer W Hex nut 5/6-8 W E 2 20 Cover L Instruction label (not shown) K Locknut /4-20 W Release label G * Number of rotating discs is shown in the brake model number. Example has two rotating discs. The number of stationary discs is one more than the number of rotating discs. **Part number is determined by one or more of the following: model number, voltage, motor shaft diameter and keyway size. 28

30 Torque Adjustment Caution: Load to be removed or blocked. Brake may be inoperative during this procedure. The magnetic disc brake is factory set for rated static torque. The brake can be adjusted to reduce torque which increases stopping time. Do not attempt to adjust brake for higher torque, as this will cause premature coil burnout. (Refer to Fig. 3). To adjust, remove cover locknuts (22) and cover (20) to expose torque locknuts (5T), which are above torque springs (5S). 2. To increase stopping time and reduce torque, turn two locknuts (5T) counterclockwise, increasing spring length. Each full turn reduces torque 7% to 0% depending upon the model. Friction Disc Replacement Caution: Load to be removed or blocked. Brake will be inoperative during this procedure. If brake model number has a prefix VO or VU, see page 8. When total wear on a rotating friction disc (3) reaches /6, replace disc:. Removing operator assembly Disconnect power. 2. Remove cover locknuts (22) and cover (20). 3. Remove operator assembly (5) by removing screws (6), pivot stud (0), washer (8), bushing (7), and spring (). NOTE: Item (0) has a hex socket in end of stud for removal. Do not loosen nuts (9) on pivot stud (0), or Pivot Stud Adjustment (on page 6) to quiet the magnet will have to be made. 4. Replacing the friction disc Remove worn rotating discs (3) and stationary discs (2). Replace worn discs and install new discs in the same order. Install stabilizer clip (4), if furnished, on rotating discs prior to installing. 5. Re-assembly of operator assembly (5) Refer to Figs. 3 and 9. (Capscrew (6) is shown in Fig. 9 and not Fig. 3) Turn two screws (5H) counterclockwise five turns. Place operator assembly onto brake bracket (2) and install two screws (6). Replace compression spring (), bushing (7), washer (8), and pivot stud (0) which has the two nuts (9) in place. Tighten firmly. 6. Readjust magnet air gap A as described under Wear Adjustment on page Check manual release operation before completing installation. Adjust per Manual Release Adjustment on page 7 if required. 8. Completing installation Replace cover (20) and cover locknuts (22). Tighten just enough to hold the cover in place. Reconnect power. Figure 4 Magnet Assembly Replacement Caution: Load to be removed or blocked. Brake will be inoperative during this procedure.. Disconnect power supply. 2. Remove cover locknuts (22) and cover (20). 3. Remove two capscrews (5D), magnet assembly (5A) and shock mount (5B). 4. Replace with new magnet assembly (5A), making sure shock mount (5B) is in place. Feed coil lead wires through hole in back of bracket (5C) as shown in Fig. 4. TIghten mounting screws (5D) with lb. in. torque. 5. Place coil lead wires around mounting bracket (5C) to the same side as the wire outlet position. Connect coil lead wires per Connection of Coil Leads and Fig Set air gap A as described under Wear Adjustment on page Energize coil. Magnet should be quiet; if not, refer to Pivot Stud Adjustment on page Check manual release. If it does not operate properly, adjust as outlined under Manual Release Adjustment on page Replace cover (20) and cover locknuts (22). Tighten just enough to hold the cover in place. Reconnect power. 29

31 TROUBLESHOOTING CHART SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Brake does not release. Broken or damaged parts. Replace. 2. Wrong voltage 2. Check for correct voltage. Voltage must correspond to that listed on brake nameplate. If the voltage is more than 0% below the nameplate voltage, the magnet may not pull in. 3. Burned out coil 3. Replace magnet assembly (5A). 4. Incorrect wiring connections or 4. Find the connection or wiring fault. broken wires Correct or repair as required. Brake does not stop. Broken or damaged parts. Replace. properly 2. Worn friction disc 2. Replace disc if worn to /8 thickness. If disc replacement is not required, adjust air gap. (Refer to Wear Adjustment section.) 3. Hub positioned incorrectly 3. Relocate hub () and key, if required. (Refer to Installation section.) 4. Bake is manually released 4. Determine if manual release is in normal position. Brake chatters or hums. Dirty magnet faces. To remove dirt, insert a clean sheet of paper between faces and energize brake. Move paper around between faces to dislodge dirt, then remove paper. 2. Magnet faces are not parallel in 2. See Pivot Stud Adjustment section. closed position 3. Loose or broken shading coil 3. Replace magnet assembly (5A). 4. Wrong voltage supply 4. Check for low voltage. Manual release does not. Broken or damaged parts. Replace. work 2. Improper setting 2. See Manual Release Adjustment section. 30

32 VERTICAL MOUNTING Installation and adjustment of the vertically mounted brake is the same as on the standard model. Friction Disc Replacement When replacing friction discs, follow procedure outlined on page 5 with this addition: Care must be taken to insure proper insertion of disc separating springs. Springs are color coded for easy identification, and reference is made to spring color (see Figs. 7 and 8). Since the installation order of the disc springs is dependent on brake mounting position (above or below motor), it is important to consult the correct diagram for spring location. Qty. of Parts Item Part (determined by no. of rotating discs) No. Description No. 2 3 Spring (silver) G Spring (black) G Spring (bronze) G Roll pin-/8 x 5/8 W Roll pin-/8 x W Roll pin-/8 x 3/8 W Stationary disc H Stationary disc H Figure 7 Parts for Vertical Mounting Figure 8 3

33 Wiring Diagrams Figure 2 Connection of Coil Leads After securing the brake to the motor, connect coil leads for proper voltage per wiring diagram (Fig. 2 shows dual voltage coil). Incorrect connection can result in brake failure. CAUTION: The voltage supplied to the coil must match the voltage that the coils are connected for, or the coils will burn out. Single voltage coil: Connect brake coil leads to any two line leads (single or three phase) of same voltage and frequency as brake. Dual voltage coil: Connect leads 2 and 4 to any two motor line leads (single or three phase) of same voltage as brake. Connect leads and 3 as shown for voltage desired. Brake must be energized with motor. OPERATION These brakes are spring set devices with an electrical (magnet) release. They contain a rotating friction disc which is driven by a hub mounted on the motor shaft. When energized, the magnet compresses the torque springs, removing the force pressing the stationary disc and friction disc together. This permits free rotation of the shaft. If brake torque rating is higher than motor full-load torque rating, use brake rating rather than motor rating when selecting other drive components. Take the following precautions when operating the brake:. Do not operate the brake at higher than normal static torque capacity. 2. For applications with high inertia-type loads or rapid cycling, the thermal capacity of the brake must be considered. 3. High start-stop rates may damage motor. Consult motor manufacturer if high cycling rates are expected. 4. Be sure power supply conforms to electrical rating of brake. Manual Release The brake is equipped with a manual release. Turn the release knob (3) clockwise to stop position to release the brake. The brake will remain released until the release knob is turned counterclockwise (approx. 65 o ) or until the brake coil is energized, automatically resetting the brake. WARNING: Observe proper safety precautions in applications where a brake failure would allow the load to move in such a manner as to injure personnel. KEEP PERSONNEL AWAY FROM LOAD AREAS. 32

34 Spring-Set Disc Brakes P/N effective 4/5/99 Installation and Service Instructions for 56,000 Series (rev. A) Manual Adjust Brakes Typical Nameplate Model number Torque lb-in Mounting 20 HORIZ Volts Hertz Rexnord Corporation, Stearns Division Milwaukee, WI (44) Important SEE INSTALLATION AND SERVICE SHEET OF INSTALLATION LABEL INSIDE OF HOUSING BEFORE INSTALLING, OPERATING OR SERVICING BRAKE Rev BQB A Note: MODEL NUMBER will appear on brake nameplate. Serial number 3655C Amps Inrush.5.8 Amps holding.3. LR 6254 REVISION CONTROL (if applicable) and brake serial number Please read these instructions carefully before installing, operating, or servicing your Stearns Brake. Failure to comply with these instructions could cause injury to personnel and/or damage to property if the brake is installed or operated incorrectly. For definition of limited warranty/liability, contact Rexnord Corporation, Stearns Division, 20 North Broadway, Milwaukee, WI 53202, (44) Caution. Installation and servicing must be made in compliance with all local safety codes including Occupational Safety and Health Act (OSHA). All wiring and electrical connections must comply with the National Electric Code (NEC) and local electric codes in effect. Tools required for installation and servicing: 3/8 hex wrench 5/6 nut driver 5/6 hex wrench /4 screwdriver 3/6 hex wrench 8 adjustable wrench 2. Do not install the brake in atmospheres containing explosive gases or dusts. 3. To prevent an electrical hazard, disconnect power source before working on the brake. If power disconnect point is out of sight, lock disconnect in the off position and tag to prevent accidental application of power. 4. Make certain power source conforms to the requirements specified on the brake nameplate. 5. Be careful when touching the exterior of an operating brake. Allow sufficient time for brake to cool before disassembly. Surfaces may be hot enough to be painful or cause injury. 6. Do not operate brake with housing removed. All moving parts should be guarded. 7. Installation and servicing should be performed only by qualified personnel familiar with the construction and operation of the brake. 8. For proper performance and operation, only genuine Stearns parts should be used for repairs and replacements. 9. After usage, the brake interior will contain burnt and degraded friction material dust. This dust must be removed before servicing or adjusting the brake. 33 DO NOT BLOW OFF DUST using an air hose. It is important to avoid dispersing dust into the air or inhaling it, as this may be dangerous to your health. a) Wear a filtered mask or a respirator while removing dust from the inside of a brake. b) Use a vacuum cleaner or a soft brush to remove dust from the brake. When brushing, avoid causing the dust to become airborne. Collect the dust in a container, such as a bag, which can be sealed off. General Description These series of brakes are spring-set, electrically released. They contain one or more rotating friction discs (4) driven by a hub (6) mounted on the motor or other shaft. Operating Principle These series contain one or more friction discs (4) assembled alternately between the endplate (2) friction surface, stationary disc(s) (3) and pressure plate (also called stationary disc) (3). The stationary disc(s) are restrained from rotating by being keyed into the endplate. With the brake released, all disc pack components are free to slide axially and the friction disc(s) to rotate. Brake release occurs when the solenoid coil is electrically energized, causing the solenoid plunger to travel a specified distance and through a lever system, overcoming the pressure spring force. This action releases the clamping force on the disc pack, thereby allowing the friction disc(s) and brake hub to rotate. Brake sets and torque is produced when electric current to the solenoid coil is interrupted, thereby collapsing the solenoid magnetic field. The solenoid plunger returns to its original de-energized position allowing the lever arm to move forward by virtue of the compressed torque springs. This action compresses the disc pack components which applies a retarding torque to the brake hub and ultimately restores the brake to a spring-set static condition. Caution! While the brake is equipped with a manual release to allow manual shaft rotation, the motor should not be run with the manual release engaged, to avoid overheating the friction disc(s).

35 BRAKE MOUNTING (Manual Adjust) Œ Place hub on motor shaft. Position hub on shaft as shown. Ž Tighten set screws to motor shaft. Remove brake housing. Slide endplate over hub noting position of stabilizer springs, if used. (Refer to Friction Disc Replacement, view 4 and 4A.) counterclockwise or Mount brake endplate to motor C-face. Connect coil leadwires to power supply. Refer to nameplate for voltage rating.* Caution: Keep wiring away from pinch points and moving components ft.-lbs. 80 * For vertical assembly of 20 & 25 lb-ft brakes, refer to page 5. Replace brake housing and tighten to 8 in-lb. *For DC voltages see sheet clockwise 34

36 Œ To increase air gap, turn adjusting screw (0) counterclockwise. AIR GAP ADJUSTMENT Series 56,000 As friction disc wear the air gap will increase. When plunger gets to the reset position, the air gap must be adjusted. To decrease air gap, turn adjusting screw (0) clockwise. counterclockwise counterclockwise clockwise FRICTION DISC REPLACEMENT Series 56,000 Œ Remove brake housing. Remove support plate screws and lift support from brake. Ž Remove and discard old friction disc. counterclockwise Install new friction disc(s) and stationary disc(s) as shown. 4A * Correct * Wrong WRONG * Stabilizer springs are for use on single disc units only. Position springs opposite set screw holes. WRONG *For brakes with vertical springs see page 5. Reposition support plate on endplate and Reposition housing and tighten nuts to 8 in-lbs. tighten mounting screws to 55 in-lb. clockwise clockwise 55 in.-lbs. 8 in.-lbs. 35

37 Œ Remove brake housing. COIL REPLACEMENT Series 56,000 Disconnect coil leadwires from power source. counterclockwise Ž Insert screwdriver between support plate and lever arm and pry forward. Lift plunger/solenoid lever assembly out of coil. Remove plunger guide. Discard coil. A) Insert new coil. (Lead wires in same position as old coil.) B) Insert plunger guide. A) Reinsert plunger into coil; drop pivot pin into cradle of support plate. B) Remove screwdriver. B A B A Reconnect coil leadwires to power source. Reassemble housing. Tighten to 8 in-lbs. clockwise 36

38 Vertical Brake Assembly Single disc brakes (.5, 3 & 6 lb-ft) are universal mount and do not require separator springs. Double disc brakes (0 & 5 lb-ft.) universal mount but require separator springs which are preassembled to the stationary disc. These discs are inserted spring first into the brake. Refer to figure 5A below. Figure 5A Installation Procedure for 20 and 25 lb-ft brakes if mounted vertical to motor shaft (These brakes are factory assembled for horizontal operation.) Figure 5B Remove support plate by loosening the three mounting screws. Remove stationary discs and friction discs. Using the spring kit provided with this brake, insert three springs of identical color into each stationary disc hole. Springs are inserted from the side opposite the indent mark (see Figure 5B). Stationary disc should be placed on a clean flat surface with a clearance hole to allow the tip of the spring to extend through the bottom side of the support plate. Using the /8 pin provided and a hammer, drive the hold until the large coil diameter bottoms out against the disc. Figure 5C Reassemble the disc pack with the stationary discs in the proper arrangement shown in Figure 5C. Mount support plate and torque screws evenly to 55 in-lbs. Torque Adjustment Brake is factory set for nominal rated static torque which is maximum torque. Torque may be decreased up to 50% for increased stopping times up to 2 second stop time. Figure 6 R TABLE A Nominal Original Maximum % Torque Static Spring Counter- Reduction Torque Height clockwise per (lb-ft) (inches) Turns Turn -/2-3/ /2 6 -/2 0-9/6 5-/2 9% 5-9/6 20-9/6 25 -/2 The torque on the -/2 lb-ft brake may not be reduced. Turn both adjustment nuts (), Figure 6, equal amounts counterclockwise to decrease torque. See Table A for torque reduction permissible amounts. General Maintenance Warning! Any mechanism or load held in position by the brake should be secured to prevent possible injury to personnel or damage to equipment before any disassembly of the brake is attempted or before the manual release knob is operated on the brake. Observe all cautions listed at the beginning of this manual before attempting to service brake. Troubleshooting A. If brake does not stop properly or overheats, check the following:. Are friction discs excessively worn, charred, or broken? 2. Hub may have become loose and shifted on shaft. Recheck set screw torque. Reposition hub if shifted. 3. With brake de-energized and housing (7) removed, check compressed length of pressure springs (). Compare to Table R values (at right) and adjust to minimum height to obtain desired stop times. 4. Is solenoid air gap adjusted correctly? See Page 3 for instructions. 5. Solenoid may not be energizing and releasing the brake. Check voltage at the coil and compare to the coil and/or nameplate voltage rating. 6. Check linkage for binding. Depress solenoid plunger down to frame surface. Movement to be without binding. 7. Brake coil should be energized at same time or prior to energization of motor, and de-energized at same time or after de-energization of motor. 8. Replace friction disc(s) when worn area is one half of original thickness. 9. Check to be sure wear adjust screws are of equal height. Measure from inboard side of support plate with depth micrometer. Turn one screw to obtain equal height. B. If solenoid hums, pulls in slowly, or coil burns out, check the following:. Solenoid plunger to frame contact surface may be excessively dented. 2. Are solenoid plunger to frame contact surfaces sticky and dirty. 3. Solenoid mounting screws may have become loose, causing frame to shift and plunger to seat improperly. 37

39 Information required when ordering replacement parts: Give part number of parts or kits needed, brake model number, and brake serial number. The brake model and serial number may identify special brakes not covered by this parts list When ordering hubs, specify shaft diameter (hub bore) and keyway. Enclosure is specified as follows: NEMA (formerly referred to as standard) NEMA 4 (formerly referred to as DTWP dust-tight waterproof) NEMA 4X (formerly referred to as BISSC washdown) TABLE Components of Standard AC or DC Brake Torque (lb-ft).5 and NEMA Enclosure Brake Model Number Item Description Part Number A A B C C C2 D D DP Hardware kit - NEMA Hardware kit - NEMA 4 Hardware kit - NEMA 4X Plug/Gasket kit NEMA 4 ** Close couple NEMA 4X NEMA 4 3 disc NEMA 4X 3 disc Housing & release knob kit NEMA Housing & release knob kit NEMA 4 Housing & release knob kit NEMA 4X Stationary disc kit ( disc universal 3 disc horizontal) Stationary disc kit (2 disc universal) Stationary disc kit (3 disc universal) Friction disc kit Stabilizing spring Disc pack kit disc Disc pack kit 2 disc Disc pack kit 3 disc & and 25 4X 4 4X 4 4X 4 4X 4 4X & & /8 bore B Hub and set screw assembly 7/8 bore D & 2 disc (NEMA ) -/8 bore E E 5/8 bore B Hub and set screw assembly 7/8 bore D disc (NEMA 4 & 4X) -/8 bore E Hub and set screw assembly 3 disc (NEMA ) and 2 & 3 disc (NEMA 4 & 4X) 5/8 bore 7/8 bore -/8 bore B D E F & 2 disc (NEMA ) disc (NEMA ) Endplate and disc (NEMA 4) stationary disc 2 & 3 disc (NEMA 4) assembly disc (NEMA 4X) & 3 disc (NEMA 4X) * Certain multiple friction disc model numbers require a single stabilizer clip (D) added to each friction disc. If your brake has these clips, they must be replaced when the friction disc is replaced. This clip is included as part of the friction disc kit **Close coupled brakes identified by 8 in the 8th digit. example: -056-XXX-8X * * * * * * & * & * & * 38

40 TABLE 2 Components of Support Plate and Coil Assembly Torque (lb-ft).5 & 3 6 & 0 5 &20 25 NEMA Enclosure Support Plate Assy. (Items M through Y and EA) Item Description Part Number M N O P Q R S Bearing Solenoid lever Retaining ring Spacer Torque adjustment nut Wear adjustment screw Pressure spring Pressure spring Pressure spring Spring washer Lever arm and stop nut assy. Bearing pin Plunger stop Support plate and spring stud assembly (2 housing studs) Support plate and spring stud assembly (3 housing studs) Pivot pin Mounting screws X X S T U V X Y EA AC Brakes Z No. 4 solenoid kit AA CC No. 4 coil kit 60 Hz No. K4 coil kit 60 Hz No. K4 + coil kit 60 Hz No. M4 + coil kit 60 Hz 575 Vac Brake release interlock switch (optional) DC Brakes No. 4 + coil assembly No. K4 + coil assembly AB No. M4 + coil assembly No. P4 + coil assembly Electronic DC BB switch kit Vac 230/460 Vac 5 Vac 230 Vac 460 Vac 575 Vac Vac 230/460 Vac 5 Vac 230 Vac 460 Vac 575 Vac Vac 230/460 Vac 5 Vac 230 Vac 460 Vac 575 Vac Vac 230/460 Vac 5 Vac 230 Vac 460 Vac 5 Vdc 230 Vdc 5 Vdc 230 Vdc 5 Vdc 230 Vdc 5 Vdc 230 Vdc 24/28 Vdc 5 Vdc 230 Vdc X X TABLE 3 Contents of Kits and Assemblies Item A B C C C2 D DP E Z AA AB BB CC Kit Description Hardware kit NEMA ( ) 2 Housing acorn nuts 2 Conduit plugs Hardware kit NEMA 4 ( ) Hardware kit NEMA 4X ( ) 3 Housing nuts 3 Housing nut gaskets Endplate oil seal 2 Endplate hole plugs 2 Housing to endplate U gasket 2 Endplate conduit pipe plugs Housing & release knob kit ( X-00) Housing and release knob assembly 2 or 3 Housing nuts 3 Housing nut gasket (NEMA 4 and 4X) Stationary disc kit ( ) Stationary disc Stationary disc kit ( ) 2 Stationary discs with springs Stationary disc kit ( ) 3 Stationary discs with springs Friction disc kit ( ) Friction disc 2 Stabilizing springs (for -/2 lb-ft brake use only) Disc pack kit ( X-00), 2 or 3 Friction disc(s), 2 or 3 Stationary disc(s) 2 Stabilizing springs (for -/2 lb-ft brake use only) 3, 6 or 9 Stationary disc separator springs Hub and screw assembly all types, all bores (5-6-55X-00) Brake hub 2 Set screws No. 4 solenoid kit ( ) Plunger Solenoid link Frame Solenoid link cap screw Solenoid link nut 3 Solenoid mounting screws No. 4 AC coil kit ( XX-X3) and DC coil assembly ( XX-X3) Coil / Top Plunger guide / Wire nut DC switch kit ( X-5) Electronic switch Mounting bracket 3 Bracket mounting screws 4 Switch moutning screws 4 Nuts 4 Lock washers 5 Crimp connectors Brake release interlock switch ( ) Microswitch Mounting bracket 2 Bracket mounting screws 2 Switch mounting screws 2 Lock washers 2 Nuts 2 Lead wire assembly

41 DRIVE ASSEMBLIES IDENTIFICATION: Identifying which drive assembly you have is very easy. This manual contains information on ACE DRIVES, Benzlers & SEW-EURODRIVES. The ACE DRIVE can be identified by reading the stamped name plate on the motor or the reducer. There are very few serviceable parts to the drive assembly. If a problem exists, it is usually faster and less expensive to replace an entire motor or gear reducer rather than try to buy parts to repair unit. Contact the factory at the number listed on the front of this manual for more information. WARNING! Disconnect and lock out the power source feeding the crane mainline or other power source before attempting any service on the drive assembly. One of the most important items to keep properly adjusted is the drive assembly brake. Proper inspection and maintenance is essential for safe operation of the trolley or crane. The following information on the drive assemblies is published with the knowledge of the manufacturers and is offered as a guideline only. Ace World Companies takes no responsibility as to the content or intent of any information or instruction contained in the following section. 40

42 SPARE PARTS LIST B Reservdelslista Varaosaluettelo, Ersatzeilliste Liste depiéces de rechange Lista de piezas de recambio Catalogo parti de ricambio BTM02-23 BTM02, 2, 20 BTM03, 3, 23 4

43 SPARE PARTS LIST B Motorfläns 9 Låsring 7 Lock 25 Kuggdrev Moottorilaippa Urarengas Kansi Vetopyoörä Motorflange Locking ring Cover Pinion Motorflansch Sprengring Deckel Ritzel Bride moteur Circlips Garde Pignon Motor brida Anillo de fijacón Tapa Piñon Motore flangia Anello elastico Coperchio Pignone 2 Skruv 0 Kullager 8 Skruv 26 VK Lock Ruuvi Kuulalaakeri Ruuvi VK Kansi Screw Ball bearing Screw VK Cover Schraube Kugellager Schraube VK Deckel Vis Roulement à billes Vis VK Garde Tornillo Rondamiento de bolas Tornillo VK Tapa Vito Cuscinetto a sfere Vito VK Coperchio 3 Tätningsring Låsring 9 Kugghjul 27 Kuggdrev Tiivisterengas Urarengas Hammaspyörä Vetopyoörä Oil seal ring Locking ring Gear wheel Pinion Dichtungsring Sprengring Zahnrad Ritzel Joint Circlips Roue Pignon Anillo obturador Anillo de fijacón Rueda dentada Piñon Paragrasso Anello elastico Ruota dentata Pignone 4 Låsring 2 Hålaxel 20 Distanselement 28 Gummielement Urarengas Akseliholkki Välirengas Kytkinkumi Locking ring Hollow shaft Spacer Rubber element Sprengring Getriebehohlwelle Distanzelement Gummielement Circlips Arbre dentée Intercalaire Element de caoutchouc Anillo de fijacón Orificio del eje Distanciador Elemento de caucho Anello elastico Albero cavo Distanziale Elemento elastico 5 VK Lock 3 Tätningsring 2 Kil 29 Växelhus VK Kansi Tiivisterengas Kiila Vaihderunko VK Cover Oil seal ring Key Gear case VK Deckel Dichtungsring Passfeder Getribegehäuse VK Garde Joint Clavette Carter VK Tapa Anillo obturador Chaveta Cubierta del engranaje VK Coperchio Paragrasso Chiavetta Carcassa riduttore 6 Låsring 4 Låsring 22 Sekundär fläns 30, 3 Kugghjul Urarengas Urarengas Laipparakenne Hammaspyörä Locking ring Locking ring Output flange Gear wheel Sprengring Sprengring Abtriebsflansch Zahnrad Circlips Circlips Bride côte arbre Roue Anillo de fijacón Anillo de fijacón Brida con eje de salida Rueda dentada Anello elastico Anello elastico Flangia uscita Ruota dentata 7 Kullager 5 Kullager 23 Skruv 32 Kuggdrev Kuulalaakeri Kuulalaakeri Ruuvi Vetopyoörä Ball bearing Ball bearing Screw Pinion Kugellager Kugellager Schraube Ritzel Roulement à billes Roulement à billes Vis Pignon Rondamiento de bolas Rondamiento de bolas Tornillo Piñon Cuscinetto a sfere Cuscinetto a sfere Vito Pignone 8 VK Lock 6 Packning 24 Kullager 33 Kullager VK Kansi Tiiviste Kuulalaakeri Kuulalaakeri VK Cover Packing Ball bearing Ball bearing VK Deckel Packung Kugellager Kugellager VK Garde Joint Roulement à billes Roulement à billes VK Tapa Empaquetadura Rondamiento de bolas Rondamiento de bolas VK Coperchio Guarnizione Cuscinetto a sfere 42 Cuscinetto a sfere 36 Ingående axel Ensiöakseli Input shaft Antriebswelle Arbre d'entrée Eje de entrada Albero d'entrata

44 Mounting GENERAL. The gear should be placed on a flat and solid foundation. 2. Sprocket, pulley or coupling on shaft can not be mounted with force. This will damage the gear. 3. To avoid increasing load on shafts and bear- ings, the gear and the driven machine should be carefully aligned, even if an elastic coupling is used. HOLLOW SHAFT GEARS. The gear is normally mounted on a shaft with tolerance js6. The hollow shaft have tolerance H7. Grease the shaft with Molykote BR2 or equivalent before the gear is mounted. The gear shall not be mounted with force. The gear shall be locked against axial movement. Set screws in hollowshaft can be used for BS88 and If sprockets are used on the output shaft the preferable direction of pull should be such that the gear housing will be pressed towards the foundation. 5. When situated outdoors or working under adverse conditions as heat, dust or damp, the gear must be provided with sufficient protection, but the cooling air circulation must not be unduly restricted. Lubrication Before delivery BS40-2 are filled with synthetic oil-mobil SHC 634 and BS35 with synthetic grease- Mobil SHC 007. This type of lubrication is extra suitable for worm gears. At normal condition the oil/grease never needs to be changed. Ambient temperature -30 C +30 C Maintenance. Benzler worm gears are lubricated for life with synthetic oil/grease and are therefore maintain- ance free. 3.. The worm gears shall under no circumstances be entirely filled with oil or grease. 2. Check that there are no leakages. Running In. The gear should be run under low load conditions during the first 0-30 hours. Then the load should gradually be increased to full load. 2. The length of the running-in period depends on the size of the gear and the actual working conditions. 3. When increasing the load the temperature of the gear can exceed the ambient temperature by C. Oil-and gear temperatures of C are harmless and have no influence on the function of the gear. When the temperature exceeds 00 C special seal rings must be used Gears which are not used for a long period should be run for short periods, approximately every third month.

45 General I. The ge<lr motor is lifted by c s:rcp c::ccned 0 Ihe hole ror the torque erm brocket end Ine mo:et. Do no! Ill: the gecred moloi by Ihe motor linin9 plug only. 2. The reducer should normolly be mounted en 0 shoh wirh lolercnce js6. The hollow shoh hos tolercnce H7. Greese shaft with Molykote SR2 or corresponding before mounting me speed reducer. 3. Tne speed reducer must nol be forced onto the,hofr. Use c threaded hole in Ihe mochine shan ond c threeded bolt ond 0 wesher (Fig ). 4. Rubber elements ore ouembled cnd pre!ensioned to corr~i dimension (to) according to poge 9. S. AI mounting Ihe oilleve! plug. filling plug ond draining plug must be reacheble for the oil chonging_ 6. Geers rnotlnted QU!dOCl IS or lhol sholl be working under crdous co"diliol'l5. such os hot. dusty or we! enyiro~me,,!. should be equipped with proper protec:icn. Air circulorion orou"d the Ee::lr shell nol be stopped'. 7. Air plug shall be placed in Ihe highesl situated oil plug. Top simplify oilleyel check en oil level glass is ClvoilClble ogoinsl seperote order. Consult Benzlers for more informotion. lnstaation ACE-DR' Dismounting (Fig 2J. Remove bol!. wosher end leckit:g ring. 2. Remeve rubber elements 3. Use Benzie,s Dismounting Kil or similar preper details 0 dismount the gecr from machine shaft (see below). Maintenance. BOlh oil ond greclse should be repleced Clner epprolcimotly operation hours at on oil temperoture a! +60 C. If Ihe oil temperature is higher or lower. the inlervols between oil replccemen:s will, - cecreose or 'ncreose. 2. AI cleaning. the gear housing should be flushed with the some wrt 0 oil thai is used under working condilior.s. 3. Check oil leyel 0 regular inler~cls (0: slone slill). The cil sholl reach the correct oil leyel plug. See page 2 depending on mounting position. A. The geared motor musi never be filled entirely wi:h oil or grease irrespecliye of ils mounling position. rurther j"formation see the Installation and Mointenonce instruction. Fig rig 2 I "G - ~, ry~ d"'! C!.~ I" " I ; H I I " 33 " 24_5 34.S " " " A3 60 " 02. OJ 2S 2S,,~ 24.S :::0 30 2U 29.S '0 ' I! Tne cim.nsion l3 is 0 simpl.e g uiceline. II con be dilireni p~,o,dir'9 Ie the cus:ome's reqlliremen:. " 20 " ~ I I I " L5 I IT 63 :;S 30 9 '0 60 '" 99 '" 60, SO " '26 M' M' MIO, M2 M6 '" M2 5 so,,, ,,, I.S,, M",,, -Cop.4 _ Driven shaft 2 - Screw TE UNI Screw AM UNI 605() Threcded hole UN! 322 BTM02,2,~, I '0 " 44

46 Lubrication I. Tne geared ",ororl ore normally delivered with oil c:::::or:lln9 0 ordered mountins?osition. If no mounting posi;ion is SIYen the 9:0r5 ore delivered occording to mounting poshio" Hi Isee below). Differen! mounting posificn require differenr oil velumes. 2. The georee morers ore normcly delivered with oil type ISO VG 220 EP 0: minercl type, if nothing else is specified by purchaser. 3. Recommended oil in accordance with viscosity grade ISOVG: Ambie nt te mperature -20'C -+ lo- C ",5~ c +30 ~ C -ly c + 40~ C Oil type ISO YG 68::? ISOVG 220 EP ISO VG 50 Synthetic Fot other ombienl le mpe rature end / or output speeds please consult Benzlers. A. For greose IJbricoled geers, greese in accordonce wilh NlGI ().OQ is recommended with minimum besic viscosity ISO VG ombient temperoture ly C C. Quantity of oil and oil level plugs BTM I HI H2 I "3 I H< I H5 I 0' I I., I.' '0 2.' < 3.0 < I.S 23,., < 3.0 < H6.0 ' '.0 3.c If il is required to mo unt c gear unit in any other position, Benzlers should fint be consulted. Note! Lubricants' of mineral type shall not be mixed with those of synthetic type. Check oil level before new oil is filled Hl ~. ~ q~o,...:-;--=-,. H2 r" _ ~ i---j.;..: I ~ I """ -- --_.=-_.-, ~. r'~'" - I. ~ II-"='" :':~" '; -;.~~ \.. -ill j... i ~ '-><== ;,.. ' =-=>- -~'7.7 I F:::s II,,-. ;;. - I \- -:} '- '~' i.-. ~~...;-J?J'V= ~ H4 H5 = ~ =7_.; /~ '., j... '-:e.:.l.~.~./.-- ~ r'l"~ -- romr OOscilJ t~ / il '<i I n '-../ Fill a nd brea ther plug ~ Qillevel plug :;.. L. -il, I! I H3 H6 v ~... -'\OS.. ;.! //}. Drain plug 45

47 Mounting Ge ne ral LTne g!!ored mot::.r is liflee by 0 strap ol:ocnec 0 the hole br me torg ve arm brocket and the motot. DQ nor fir. the geared moio: by me mobr Iiftil'l9 lug only. 2.Th! reducer snould normally be mounted on 0 shah wim ~ o! e fonce i~6. rne hollow Mlan hos toleronce H7. GreesE shaft with Molykote BR2 or carrespondin; belore moollting the s;>eed reducel 3. The speed reducer must net be Fcrced onto Ihe shaft. Use a thre!lded hole in Ihe machine sholr ond a threaded bolt and 0 wosner(fig ). 4J!ubber elements ere ouembled end preiensioned to coned djmen~ion (lo). S.At mounting me oil level pl!jg. filling plug and draining plug must be reachable lor the oil chonging. 6.(3eQrs mounted outdoors or thet sholl be worir;ing under ord::us conditio!"!', such os hot, du~ or wei erwirl;mmel\!, sholjld be equipped with proper protedion. Air circulction around The gear sholl '0 ~ ~Iopped. 7.Air plug which is supplied 0' reque5tlhall be placed in the highest sill::jted oil plug. To simplify oil level check ell'l oil level glc:;.jo is availacle against separate areer. Consuh Senzlers for more information. Dismounting (Fig 2) I.Remove bah, washer ond locking ring. 2.P.e move rubber elements 3.Use Benzlers Dismounting Kit or similar proper details 0 cismou:li me gear fmm machine shalt. Mounting of (KIBO) tapered bushing (fig 3) for corree mounting of the speed redu::er it is imperlont thot both bushi:lgs obtoin me same pre5sing force.. Mount the inner bushing with The nut in ils ouler position. Th!! bushing $hall be mounted 090in the shoulder or cirdip. 2.Pul the key in the keyway. 3.Moun! the reducer on the machine shalt cnd pre.m it ogoinst the innef bushing. A.Moun: the ou~r bushing with the nut in it's inner position. Check so tha t the bushing is not squeezed bul the nut is in conloo with th!! shaft sleeve. S_Mount th;! washer with it's boll. Tighten the boh with col"fed torque. roe inner cushing is now locked. 6 _loosen the bah. 50 the outer bushing is loose. Tum out the nut on the bushing. 7_Tighi"en the bah on::e ogoin with corred to rque. Tne outer bushing is!low locked. S.Screw The nuts against the hollow sholt by hand. mounting is complete. Dismounting of KIBO. I.loosen Ihe bolts ond lake away me wosh!!f. 2.Pull out me auler bushing with the nu l, U$e a screwdriver. Toke cui me bushing. 3.Fre5S the reducer from the inne r bushing with the nut, dismoun:ing is complele. Mounting atm. 22 BTM I EK 6 6 " DE 40 ""' 6 50 M 6 60 M20 90.~, Fi9""" l I DK I EF I GA I FF I KA I KH I KB ' " " ".!-!,5 " '-' 9 ' S

48 , I'i L- \?--==-iit -'-- Tightening torque for KIBO Size Tightening torque BTM Nm 32 lob Nm Nm Nm 8 Wosner 82 Nul 83 SuIt 8-! Key 8S Tapered bu~h MCiintenance.Doth oil ond greq~ should be replcced af:er cppro"imctely operotion hou~ 0 en oillemperol'llre c:.60<c. II me oil h!!mperc'fure is higher or 0000r. tht- in:ervols berween oil replccemenls will oe"jeme c: increase. 2.Af dec:ling, the Seer housing snculd be Mushed with the 5c:ne son of oillhet is ",sed under wol'iing conditioru. 3.ChKk oil l.yel at fegulc~ il'l:'ervci5iai5jond ~rl. Tne oil sholl reach me coned oil level pl"'9. Sa page 54 depending on mounting position. A.rne g~red rector musl never be Fillee enrirely with oil or greose irlltspect;ve 0 its mouniing position. Further intormclion see me Inslonct.ion end N.aintenonce insl'njdion. Maintenance 47

49 Installation. The geared motor is lifted by a strap attached to the gear casing and the motor. Do not lift the geared motor by the motor lifting lug only. 2. The geared motor must be mounted on a flat and solid foundation. 3. Sprockets, pulleys, wheels or couplings to be fitted on shafts must not be hammered on, as this may damage the bearings. Coupling halves, etc. must be heated up or an output shaft be pressed into position with screw, washer and nut. 4. To avoid increasing load on shafts and bearings align the geared motor and driven machine carefully even when using a flexible coupling. Maintenance. Both oil and grease should be replaced after approximately 20,000 operations hours at an oil temperature of +60 C. If the oil temperature is higher or lower, the intervals between oil replace- ments will decrease or increase accordingly. 2. At cleaning, the gear housing should be flushed with the same sort of oil that is used under working conditions. 3. Check oil level at regular intervals. The oil should reach the correct oil level plug. 4. The geared motor must never be filled entirely with oil or grease irrespective of its mounting position. Tightening torque for bolts and nuts (Nm) Size M6 Bolt Nut *Quality 8.8 M8 M0 M2 M For further information use Benzler maintenance instruction or contact Benzler office. For motorservice use instruction made by motor manufacturer. Lubrication. BG 2 gears are delivered filled with a synthetic oil Mobil SHC 634. For normal conditions the supplied lubricant is for life. Ambient temperature -30 C to +30 C. All geared motors are normally delivered with oil according to mounting position specified by purchaser. If no mounting position is speci- fied, geared motors will be supplied filled with oil for B3 mounting. Note that different mounting positions require different oil quantities. 2. The geared motors are normally delivered with oil type ISO VG 220, if nothing else is specified by purchaser. 3. The geared motors are provided with labels which indicate the mounting position and the grade of oil used. 4. The inner bearings are oil lubricated. The coupling shaft bearing and the outer bearing of the slow speed shaft are always lubricated with ball bearing grease. Recommended oil in accordance with viscosity grade ISO VG: Ambient temperature/type of oil -20 C - +0 C + 5 C C -5 C C Synthetic: For grease lubricated gear units: -ISO VG 68 EP -ISO VG 220 EP -ISO VG 50 SYNTHETIC -5 C C Grease in accordance with NLGI 0-00, minimum ISO VG 320 N.B. Mineral oils must not be mixed with synthetic oil. Different grades of grease are, as a rule, not mixable. 48

50 Motors and Brakemotors Type BM (G) Brakes OPERATING INSTRUCTIONS US Every SEW-Eurodrive motor is thoroughly tested, checked, and properly packed prior to shipment. However, please check immediately upon arrival for shortage of parts or transit damage. Note the damage or shortage on the freight bill of lading and file a claim with the carrier. Also, notify SEW-Eurodrive of the shortage or damage. For motors mounted integrally to a gear unit, please refer to the Operating Instructions for Gearmotors and Gear Reducers for proper installation of the drive. The drive installation site should be selected to ensure: Ambient temperatures below 40 C (04 F). Unimpeded flow of air to the motor and variable speed units. Accessibility to gear unit, oil plugs. Adequate space for the removal of the brakemotor fanguard for brake adjustment and maintenance. The drive unit should be mounted on a flat, vibration damping, and torsionally rigid structure. The flatness tolerance of the supporting surface should not exceed: For motor size 80 and smaller inch For motor size above inch Do not hammer on the shafts to install couplings, sheaves, etc. Hammering can cause brinelling of the bearings and a reduction in bearing life. We recommend heating the components to approximately 75 F and sliding them on. This will reduce possible damage to the bearings. In addition, there is a metric tapped hole in the center of the motor shaft that can be utilized with a tool to press on or remove the coupling, sheaves, etc. The motor shaft diameters are metric and have tolerances as listed in the SEW-Eurodrive catalogs. Shaft couplings should be properly aligned to prevent vibration, coupling wear and premature failure of the shaft bearings. Maximum Parallel Offset inch Maximum Angular Offset To prevent the output shaft and bearings from being subjected to excessive loads, the maximum overhung loads, as shown in SEW-Eurodrive catalogs, should not be exceeded. Please consult our engineering department if the load may exceed the recommended figure given or where there are combined radial and axial loads. In such cases, the exact operating conditions must be stated including speed, direction of rotation, position, magnitude and direction of the external radial and axial loads being applied. If the motor must be stored for a long period of time without operating, the motor must be stored in a dry, protected area, and in the mounting position indicated on the unit nameplate.in order to ensure that the motor has not been damaged by moisture after a prolonged storage, the insulation resistance should be checked. An insulation tester with a measurement voltage of at least 500V (e.g. magneto generator) should be used for this purpose. The insulation resistance is sufficient if it has an ohmic value of at least 000 x V N (e.g. at V N = 230VAC: R insul ohms = 0.23M ohms). If the measured value is smaller, the motor should be dried before use (for example, with hot air up to a maximum of 90 C or by resistance heating with an auxiliary AC voltage of 0% of V N via an isolating transformer). Care should be taken to ensure that the motor is heated with not more than 20% of its rated current and that the rise in temperature is not more than 90 C. The drying procedure can be stopped when the insulation resistance has reached = 0.5M ohms. Severe Duty Units are indicated with the letters -KS at the end of the motor type on the motor nameplate. Severe Duty units include drain holes in the motor end bells and conduit box at the lowest points allowing condensation to drain out of the motor. The drain holes are installed for the mounting position listed on the -gear box nameplate. Installing a unit in a mounting position other than what is shown on the nameplate will reposition the condensation drain holes. As a result, the drain holes may not be located at the lowest point and may not allow water to drain. This can cause premature drive failure. The motor must be installed and connected by a qualified electrician who is knowledgeable with the NEC article 430 and local regulations. He must make sure that the voltage and frequency of the electrical supply correspond with the data stamped on the motor nameplate before connecting the motor in accordance with the wiring diagram, which can be found in the terminal box. For brake connections, see the following pages. At installation the electrician must make sure that the terminal block jumpers are positioned correctly and that all electrical connections including the ground connection are secure. In order to effectively protect the motor from overloads, appropriate motor protection must be provided. Fuses do not always provide adequate motor protection. For motors which are required to operate with a very high start-stop frequency, the overload heater type motor protection is insufficient. It is advisable in such applications to provide the motor with temperature sensors (thermistors) in the windings. Monitor the thermistors by means of an external trip device. In this way, the motor will be fully protected against practically all possible overloads. When using motors outdoors or in washdown applications the cable entries into the terminal box must be directed downward to prevent water from entering the conduit box. The unused cable entries must be closed off properly. Always ensure equipment is secure and electrical power is off before removing or performing maintenance on the drive assembly. The motor bearings are sealed and the grease content is adequate for the life of the bearing. SOUTHEAST MANUFACTURING & ASSEMBLY CENTER 295 Spartanburg Highway/Lyman SC (864) Fax: (864) MIDWEST ASSEMBLY CENTER 200 West Main Street/Troy OH (937) Fax: (937) WEST COAST ASSEMBLY CENTER San Antonio Road/Hayward CA (50) Fax: (50) SOUTHWEST ASSEMBLY CENTER 3950 Platinum Way/Dallas TX (24) Fax: (24) EAST COAST ASSEMBLY CENTER 200 High Hill Road/Bridgeport NJ 0804 (856) Fax: (856)

51 Mounting Positions and Important Order Information General information on mounting positions Mounting position designation Mounting Positions SEW differentiates between six mounting positions M - M6 for geared motors. The following figure shows the spatial arrangement of the gear units in mounting positions M - M6. R.. F.. K.. w.. s.. Fig. 8: Depiction of mounting positions M - M6 uses 002 0~ EURODRIVE 50

52 Gearmotors and Gear Reducers OPERATING INSTRUCTIONS US GENERAL LUBRICANTS LONG TERM STORAGE INSTALLATION OF COMPONENTS ON DRIVE SHAFTS SHAFT MOUNTED REDUCERS Warning! INSTALLATION AND OPERATION MAINTENANCE Warning! SOUTHEAST MANUFACTURING & ASSEMBLY CENTER 295 Old Spartanburg Hwy, Lyman, SC (864) Fax: (864) SOUTHWEST ASSEMBLY CENTER 3950 Platinum Way, Dallas, TX (24) Fax: (24) MIDWEST ASSEMBLY CENTER 200 West Main Street, Troy, OH (937) Fax: (937) EAST COAST ASSEMBLY CENTER 200 High Hill Road, Bridgeport, NJ 0804 (856) Fax: (856) WEST COAST ASSEMBLY CENTER San Antonio Road, Hayward, CA (50) Fax: (50)

53 WARNING: Brake performance and features must be carefully matched to the requirements of the application. Consideration must be given to torque requirements, especially where an overhauling condition exists, as well as thermal capacity, ambient temperature, atmospheric explosion hazards, type of enclosure and any other unusual conditions. Improper selection and installation of a brake and/or lack of maintenance may cause brake failure which could result in damage to property and/or injury to personnel. If injury to personnel could be caused by brake failure, additional means must be provided to insure safety of personnel. UNPACKING When unpacking the brake, inspect it carefully for damage that may have occurred during transit. GENERAL SAFETY INFORMATION NOTE: These brakes are not intended for accurate positioning applications. They are designed for applications that require rapid stopping and holding power, such as on conveyors, door openers, etc.. For applications with high inertia-type loads or rapid cycling, the thermal capacity of the brake must be considered. 2. Observe all local electrical and safety codes, as well as the National Electrical Code (NEC) and the Occupational Safety and Health Act (OSHA). 3. Brake motors and brake gearmotors must be securely and adequately grounded. This can be accomplished by wiring with a grounded metal-clad raceway system, by using a separate ground wire connected to the bare metal of the motor frame, or other suitable means. Refer to NEC Article 250 (Grounding) for additional information. All wiring should be done by a qualified electrician. 4. Always disconnect power before working on or near a brake motor, a brake gearmotor, or its connected load. If the power disconnect point is out of sight, lock it in the open position and tag it to prevent unexpected application of power. 5. When working on the brake, be sure the load is completely removed, secured or blocked to prevent injury or property damage. 6. Provide guarding for all moving parts. 7. Be careful when touching the exterior of an operating motor, gearmotor or brake. It may be hot enough to cause injury or to be painful. This condition is normal for modern motors, which operate at higher temperatures when running at rated load and voltage. 8. Protect all electrical lead wires and power cables against contact with sharp objects or moving parts. 9. Do not kink electrical lead wires and power cables, and never allow them to touch oil, grease, hot surfaces, or chemicals. INSTALLATION CAUTION: To preserve pre-alignment of rotating discs for ease of installation, do not operate manual release or energize brake coil before installation. NOTE: The brakes are designed for horizontal mounting. Modification is required for vertical mounting. Brakes that are modified will have a prefix on the model number of VO (Vertical Over) or VU (Vertical Under). Numbers in parentheses refer to parts illustrated in Figs. 3, 5, 6 and 9. Mounting Hub on Motor Shaft. Remove hub () from brake and position it on motor shaft with key as shown in Fig.. Stamped part number on hub should face away from motor. Tighten hub setscrews with 8 to 0 lb. ft. torque. Placing Brake on Motor Shaft. Remove two cover locknuts (22) and cover (20). Position brake over hub on shaft, aligning hub splines with rotating disc splines. 2. Bolt brake to motor flange with four 3/8-6 socket head capscrews. NOTE: Dimension G (Fig. ) is the length of the mounting hole through brake bracket. 3. Place coil lead wires around mounting bracket (5C) to the same side as the desired wire outlet position. Connect lead wires per Connection of Coil Leads and Fig Replace cover (20) and cover locknuts (22). Tighten just enough to hold the cover in place. 52

54 LUBRICANTS LUBRICATION SCHEDULE FOR SEW-EURODRIVE GEAR UNITS Gear Reducer Type ) Lubrication Type Ambient air temperature range F ISO Viscosity Grade Mobil Oil Co. CHEVRON Oil Co. Shell Oil Co. Texaco Oil Co. BP Oil Co. Kluber Oil Co. R F K Oil +4 to to +77 VG220 VG50 VG00 Mobilgear 630 Mobilgear 629 Chevron Non-Leaded Gear Compound 220 Chevron Non-Leaded Gear Compound 50 Shell Omala Oil 220 Shell Omala Oil 00 Meropa 220 Meropa 50 BP Energol GP-XP 220 BP Energol GP-XP 00 Kluberoil GEM -220 Kluberoil GEM -50 S Oil +32 to to +77 VG680 VG220 Mobilgear 636 Mobilgear 630 Chevron Non-Leaded Gear Compound 680 Chevron Non-Leaded Gear Compound 220 Shell Omala Oil 680 Shell Omala Oil 220 Meropa 680 Meropa 220 BP Energol GP-XP 680 BP Energol GP-XP 220 Kluberoil GEM -680 Kluberoil GEM -220 General Synth. Oil Synth. Grease +76 to to -40 Consult Factory For Use of Synthetic Oils Consult Factory For Use of Grease Filled Reducers Ball & Roller Bearings Grease Used for normal application Temp. Range: -22 F to 40 F Mobilux EP2 Chevron Dura-Lith EP2 Shell Alvania Grease R3 Multifak EP2 BP Energrease LS3 CENTOPLEX 2EP ) ATTENTION 53

55 LUBRICANTS Mounting Position M M2 M3 M4 M5 M6 Gear Unit Gallons Liters Gallons Liters Gallons Liters Gallons Liters Gallons Liters Gallons Liters F F F F F F F F F F F FF FF FF FF FF FF FF FF FF FF FF FA/FH/FV27 FAF/FHF/FVF FAZ/FHZ/FVZ27 FA/FH/FV37 FAF/FHF/FVF FAZ/FHZ/FVZ37 FA/FH/FV47 FAF/FHF/FVF FAZ/FHZ/FVZ47 FA/FH/FV57 FAF/FHF/FVF FAZ/FHZ/FVZ57 FA/FH/FV67 FAF/FHF/FVF FAZ/FHZ/FVZ67 FA/FH/FV77 FAF/FHF/FVF FAZ/FHZ/FVZ77 FA/FH/FV87 FAF/FHF/FVF FAZ/FHZ/FVZ87 FA/FH/FV97 FAF/FHF/FVF FAZ/FHZ/FVZ97 FA/FH/FV07 FAF/FHF/FVF FAZ/FHZ/FVZ07 FA/FH/FV27 FAF/FHF/FVF FAZ/FHZ/FVZ27 FA/FH/FV57 FAF/FHF/FVF57 FAZ/FHZ/FVZ

56 A properly adjusted brake air gap is critical for correct operation. The following table indicates the required air gap measurement. Motor Size Brake Size Air Gap DT7 - DT00 BM(G)05 - BM(G)4 0.00"-0.024" ( mm) DV2 - DV225 BM(G)8 - BM3 0.02"-0.047" ( mm) DV80-DV225 BM32-BM62 Double Disc 0.06"-0.047" ( mm) Prolonged use of the brake will wear the brake disc lining. This wear increases the air gap. When the air gap approaches its maximum value, the brake must be re-adjusted. To re-adjust the brake, follow the procedure below.. Remove the fan cover (4), fan snapring, fan (7), rubber seal (2), and any accessories at the fan end. 2. Insert a feeler gauge between the brake coil body (2) and the stationary disc (22), tighten the adjusting nuts (9) until the minimum value for the air gap is reached equally around the brake. With motor size 60L and up (brakes BM30 to BM62) first screw the threaded bushings (24) into the endshield. After setting the air gap, lock the bushings (24) against the coil body. 3. Ensure a play of 0.06" to 0.08" (.5 to 2 mm) in the releasing arm. See THE HAND RELEASE MECHANISM. Extended operation of the brake may wear the brake disc (26) beyond acceptable limits. The thickness of the brake disc can be measured to determine if this has occurred. Motor Size Brake Size Min. Disc (26) Thickness DT7 - DT00 BM05 - BM " (9mm) DV2 - DV225 BM8 - BM " (0mm) If the brake disc (26) is worn below the measurement given, it must be replaced. If the thickness is greater than the specification above, the brake disc is still usable and the brake can be re-adjusted. Most of our brakes are supplied with a hand-operated release lever. This allows opening of the brake without applying power, allowing for adjustments on the driven machinery. There are two brake release mechanisms available: The BMHR (4) type requires a lever to be inserted into the release arm. To open the brake, pull the lever away from the motor. It will re-engage automatically, once the lever is released. The lever, when not used, is attached to the motor's cooling fins with clamps. The screw-type BMHF (5) arrangement requires a hexagon key which, when turned clockwise, opens the brake. Since the stationary disc (22) will move away from the coil body during the brake's operation, it is vital that there is free play (floating clearance) on the release arm of 0.060"-0.080" ( mm). The springs () should be placed between the arm (7) and the nuts (2) to eliminate noise. The brake release mechanism is not used to change the brake's torque - set ting. There must always be clearance on the lever. Fault: Motor does not run. Check the motor and brake wiring for damage and proper connection. 2. At the motor, measure the line voltage, line current and motor resistance of all three phases. 3. If all three phases read a similar current value the following conditions may exist: The motor may be blocked by either an excessive external load, or problems in the reducer or the brake. In both cases, the motor should draw locked rotor (in-rush) current. Consult SEW- Eurodrive catalogs for these values. Release the brake mechanically, reset the air gap if needed, or disconnect the load from the output shaft. If the brake is at fault electrically see #4 below. If the current differs significantly from the rated locked rotor current, the motor is either an incorrect voltage, or it is jumpered for the wrong voltage. 4. If the brake can be released mechanically, but does not respond to voltage, check the brake for electrical problems. Make sure the wiring is according to the instructions. Pay special attention to the brake voltage. Energize the brake circuit and measure the AC voltage on the rectifier terminals 2 and 3 (BG/BGE rectifiers). The measured voltage should correspond to the nameplate inscription: Brake V. Measure the DC voltage across terminals 3 and 5 of the brake rectifier which should be about 35% to 45% of the previously measured AC voltage. If there is no fault found to this point, measure the resistance of the brake coils. Disconnect the coil from the rectifier for this measurement. See the table on Page 2 for the brake coil resistance values. Measure the resistance of each brake coil lead to the brake coil body. This test should show an open circuit. If a short is found, the brake coil is damaged. If the results of all these checks (electrical connection, mechanical checks and adjustments, and electrical tests) indicate that the brake should work, then the most likely cause of the brake's failure to release is a damaged brake rectifier. Fault: Brake stopping time is too slow If the brake has been operating well for some time and a gradual increase in stopping time has occurred, the release arm may have come in contact with the coil body. Verify that the brake release arm end play is correct, and check for excessive brake disc wear, (see previous instructions). If the brake has been in operation for some time, and the stopping has become erratic, dust accumulation around the stationary disc guides may be the cause. Remove the brake's rubber sealing collar and clean with an air hose. If the application is new, check the brake's wiring and air gap. If the brake is not wired for fast response, then changing the brake wiring to fast response will decrease the stopping time. Vertical motion and indexing applications may also require the fast response connection. Increasing the brake's torque may remedy the situation, but will also increase stress on the transmission. On applications requiring excessive brake work, the lining's surface may become glazed due to extreme heat. The application of a BGE rectifier will improve this situation dramatically. BGE rectifiers are standard equipment on motors size DV 2 - DV225, but optional on the smaller sizes DT7-DT00. Contact SEW-Eurodrive for more information. 55

57 BM(G) Brake Cross Section and Exploded Views () Brake end shield (2) Rubber sealing collar (3) Braking springs (4) Hand release lever (5) Releasing screw (6) Closing plate (7) Release arm (9) Sealing ring (0) V-ring () Conical spring (2) Release (3) Stud (4) Fanguard (5) Grommet (6) Dowel pin (7) Fan (8) N/A (9) Brake adjustment nut (20) Retaining stud (2) Brake coil body (22) Stationary disc (23) Pressure ring (24) Setting sleeve (25) Dual brake pad stationary disc (26) Brake disc complete (27) Carrier (29) Cup Spring 56

58 Troubleshooting Chart PROBLEM CAUSE REMEDY Motor Overheats (Check temperature with instrumentation) Motor does not run. Motor will not start or starts sluggishly. For reduced voltage starting, motor will not start in Star Connection but will start in Delta connection. Motor hums and draws high current. Fuses blow or motor overcurrent protection trips immediately. Motor not connected for proper supply voltage Supply voltage varies outside the allowable tolerance causing an undervoltage or overvoltage condition. Insufficient cooling air volume due to: a. Low frequency operation on vari able frequency drive. b. Obstructed air flow. Ambient temperature is too high. Overload at rated voltage. Unit will draw current in excess of nameplate rating and run below rated speed. Motor s allowable duty cycle is exceeded (too many starts per hour required). Single phasing due to break or loose connection in supply line or blown fuse. Blown fuse. Motor protection device activated. Motor protection device faulty or will not reset. Motor not connnected for proper voltage. Large voltage and/or frequency fluctuation at starting. Insufficient torque in Star Connection. Faulty contact in Star/Delta starter. Faulty or defective winding. Rotor dragging. Short circuit in power supply conductors or in the motor. Motor has ground fault or winding to winding short circuit. Motor improperly connected. Check connection diagram on conduit box cover and correct the wiring. Assure correct supply voltage. Increase air flow: a. Continuous running auxiliary fan. b. Ensure unobstructed air flow. Ensure cool air gets to the motor. Ducting may be required. Select a larger unit. The problem may or may not be solved with a larger motor. Contact SEW- Eurodrive. Repair supply lines. Replace fuses. Determine and correct cause of failure and replace fuse. Reset protective device. Identify and correct cause for device activation. Check protection device for faults. Check connection diagram in conduit box cover and correct the wiring. Ensure stable power supply. Start motor directly in Delta Connection if possible. Otherwise use a larger motor. Correct fault condition. Have motor repaired by qualified service shop. Correct the fault condition. Have motor repaired by qualified service shop. Check connection diagram in conduit box cover and correct the wiring. Motor runs in wrong direction. Motor supply leads misconnected. Switch two supply leads. Note: If, after proceeding through the Troubleshooting Chart, the motor is found to be defective, contact your nearest SEW-Eurodrive Assembly Center for warranty assistance or replacement parts. Printed in USA

59 AM Adapter NEMA Size and lee Size GENERAL This operating Instruction pertains to the mounting or NEMA '"TC"lInd lee type motors to the A.M udopter. The A- adapter is used \0 molln! NE~A type "TC" or ree flanged mmoth \0 SEW_Eurodrh'c gear reducers. The AM adapter bas been designed 0 allow easy mounting of the motor to the adapter. The AM sile corresponds 0 the compatible ;-','EMA and lee molor fnlme designations. If you have any questions concerning this inscructioo, contact the nearest SEW-Eurodri vc Assembly Center. This operating instruction should be uso..-d together \\ith the gencral opernting ins\rol::tioo ''GePrnotors and Gear Reducers", Place the fle:<.iblc motor spider betwem the jaws of the motor coupling. Align the mowreouplingso that thejaws 00 the reducer coupling mesh with the molor coupling. The molor shaft will ejtleod into the bore of the reduecreoupling. Secure Ihe flooged motor (0 the AM adapter with Ihe required hardwan: specified by the motor manufacturer. INSTALLATION With C\'ery adopter, SEW-Eurodrh-c supplies the motor coupling btju: II key, a Ilexiblecoupling spider and mounting paste. Coal the mow shaft \\ith the mounting paste supplied by SEW (a food grade version. USDA H I, is available upon request). The use of the pllsle will aid iillbe mowting of the motor couplic.g bole as well lis allow for easier removal of!he moiotcoupling at Q later date. NOTE: The motor coupling must be mounted with the supplied parts. Fsffure to use the supplied parts could void Ihfl SEW Eurodrlve Warmnty. The mounting instructiolls for the molor coupling half are as follo\\s. Refer 0 Ihe di~gram(s) to the righ!. Remove Rny din or adhesive residue from lhe mojor shaft. Apply me SEW supplied mounting pasle 0 the molar shaft. The SEW supplied key is to be placed in the motor keyway and should be located under Ihe molor coupling. ti' ~EMA Adapter Coupling Loeation NEMA Coupling Motor Shaft Location _~_ Dimension SEW Adapter SIze I Coupling NEMA Motor Frame NOTE: The key Is not to extend beyond the coupling bore on the EITHER side. r\e\la Adapter Sizes AMS6-MJJ65 The motor coupling is 0 be mounted on the molor shaft and is to ~ located accordingly (see chart). lee Adapter SIzes A\63-AM280 The motor coupling is to be mounted 00 the motor shaft aod is 0 be localoo agairu;cthe shoulder. Tighcen the setscrew IlX.'aced on the malar collpling. SOIlTHEAST MAHUFACTlJAING &. ASSEt.tBLT CEmEA ':9500 Spo/IaI'CJutg ~. t.j.mo.' so:: 2!I3!Ii!I IIIIM) Qlo.7S.J7 Fp:: (8&0) 'J9.l3Q SOtTIfflEST ASSEMBLY CENTER $!io ~ Wi)'IDo.Ia )( = 2.) 3:JO..Q!2' "'"(2H) 33)..i;>'l' r is..{l.0 I NOTE: For mounting a motor other than a type "Te" NEMA motor to the NEMA AM adapter, pfease see operation Instruction f/ US. IrlIOWEST ASSEMBLY CENTER 200_J,,\U>s.-.&'IlojOH~ (aj7)~ l'u(93)m-<00 EAST COAST ASSEMBLT CEHTER 2IXIfg,.. ~'&dgopon ~ _.4 ill56)ui"nn Fp::{e5eJ~9 "" 58

60 ASM8 Installation and Maintenance Manual Table of Contents Table of Contents... Introduction... 2 Installation and Initial Run-in... 2 Pre-Installation Checks... 2 Installation... 2 Breather... 3 Run-in... 4 Maintenance... 4 Lubrication Types... 4 Lubricant Levels... 4 Maintenance Schedules... 5 Lubrication Tables and Figures... 7 Long Term Storage... 8 Repair, Assembly, and Disassembly... 8 Factory Information... 8 ACE World Companies, Inc. ASM8 Installation & Maintenance Manual December Page of 8 59

61 ASM8 Installation and Maintenance Manual Introduction Designed exclusively for the crane and hoist industry, the ASM8 encompasses features required to excel in such a demanding application: Tough, rugged, steel cast housing. Heat treated, alloy steel gearing. Large, oversized bearings. Standard NEMA motor adaptors. To operate trouble-free, the ASM8 relies on rugged design and construction as well as proper installation and maintenance. The following provides important installation and maintenance information for the ASM8 that will help achieve trouble-free service. Installation and Initial Run-in Careful attention must be given to the preinstallation checks, installation, and initial run-in of the ASM8. Pre-Installation Checks Prior to installation of the ASM8, verify that the nameplate information listed on the unit matches the application requirements. Verify the power rating of the unit, the ratio, the mounting position, and the hollow bore size, comparing these items to the application requirements. If a discrepancy exists, contact the factory prior to installation and operation. Record the nameplate information on page 6 of this manual for future reference. Visually check the reducer for damage that may have occurred during shipping. Do not install or operate any unit that has been damaged during shipping. The ASM8 is factory filled with lubricant prior to shipment. Unless otherwise specified, the unit is filled with Mobilgear 630 at the level corresponding to an M mounting position. Check the oil level of the unit to insure that it contains the proper amount of lubricant for the actual installed mounting position. If the oil level is low, then add lubricant as specified in figure and table 4. Installation When lifting the ASM8, do not lift by the motor or motor flange. It is best to place a strap around the reducer and lift the unit by the housing. To avoid injury, do not lift heavy objects by hand. Do not lift heavy objects by hand. Mounting Surfaces Insure the mounting surfaces for the ASM8 conform to the following: Hollow Shaft Mounted The mounting shaft must be a slip-fit in the bore of the ASM8 hollow shaft and should conform to the size recommendations found in the ASM Product Catalog. The mounting shaft must be free of nicks, burs, and debris that could cause damage to the reducer hollow bore. Lightly coat the mounting shaft with antiseize prior to installation. Flange Mounted The mounting surface must be flat and perpendicular to the ASM8 hollow bore. If piloted, the pilot bore must be a slip fit and should conform to the size recommendations found in the ASM Product Catalog. The mounting surface should be free of nicks, burs, and debris that could cause damage to the reducer or result in misalignment. The mounting surface must be sufficiently rigid to avoid excessive deflections during operation. ACE World Companies, Inc. ASM8 Installation & Maintenance Manual December Page 2 of 8 60

62 ASM8 Installation and Maintenance Manual Hammering Do not hammer the ASM8 or components mounted to the ASM8. Hammering can damage internal components or deform the housing. Do not hammer ASM8 or components onto ASM8. Tightening Torques Follow the recommended tightening torques for mounting the unit per table. Tightening Torque at Bolt Head, in-lbf Bolt Size Grade 5 Grade 8 /4-20 UNC /6-8 UNC /8-6 UNC /6-4 UNC /2-3 UNC 905,280 9/6-2 UNC,300,840 5/8- UNC,800 2,540 3/4-0 UNC 3,200 4,50 Table Bolt Tightening Torques Install the torque arm bracket to the housing as shown. Welding Do not weld the ASM8. Welding can cause internal distortions that are detrimental to the unit. Do not use the reducer as a ground during welding. Overhung Loads If the ASM8 is to be used with a sheave, pulley, or sprocket then insure that it is mounted as close to the housing as possible. Also, verify that the overhung load capacity of the reducer is sufficient for the application and installation. Torque Arm When a torque arm is required, insure that the torque arm does not over-constrain the ASM8. The factory provided torque arm adaptor may be installed in any orientation shown. Breather The ASM8 is completely sealed and does not require a breather under normal operation conditions. If the ambient temperature exceeds 20 F, then a breather is required. Elevated Temperatures When the ASM8 is exposed to direct sunlight, high humidity, or installed in an enclosure that prevents air circulation, the unit may be subjected to elevated operating temperatures. If so, insure that the unit is ACE World Companies, Inc. ASM8 Installation & Maintenance Manual December Page 3 of 8 6

63 ASM8 Installation and Maintenance Manual configured for operation at elevated temperatures. Install protective guards as required per applicable OSHA standards. Run-in It is advisable to subject the ASM8 to a partial load run-in period prior to operating the unit at full load. Operate the ASM8 at no more than 50% full load for 4 hours. After run-in, recheck the installation for proper alignment, tighten any loose bolts, and visually inspect the unit. During normal operation, the ASM8 can reach temperatures that can cause injury. Do not touch these surfaces when the unit is hot. Do not touch hot surfaces. Maintenance Long, trouble-free operation of the ASM8 relies heavily on regular and thorough maintenance. Items to be addressed include lubrication types, lubricant levels, maintenance schedules, and seasonal temperature affects. Refer to the lubricant manufacturer s product safety data sheets for proper handling and storage of lubricants. Failure to do so could result in personal, property, and environmental damage. Handle and store lubricants according to manufacturer s recommendations. Lubrication Types The ASM8 is factory filled with Mobilgear 630. Optional synthetic lubricants are available for extreme temperature applications. Completely drain and refill the unit if using a different brand or viscosity lubricant other than the factory standard. Table 2 identifies lubricant viscosity requirements and table 3 identifies alternative manufacturer s products. The lubricants in table 3 are not recommended for food and drug applications where a potential for incidental contact between the ASM8 lubricant and the product exists. The ASM8 standard seals are not guaranteed to be compatible with all synthetic lubricants listed in table 3. If synthetic based lubricants are required for the application, use fluorocarbon seals or consult the seal manufacturer for compatibility with synthetic based lubricants. Dispose of used lubricants according to federal, state, and local rules and regulations. Lubricant Levels Maintaining the proper oil level insures that all components of the ASM8 receive adequate lubrication for long, trouble-free operation. Figure and table 4 provide the ASM8 lubrication levels and volumes for various mounting positions. If it is discovered that the oil level is higher than recommended, have the lubricant analyzed for water content. The water content should not exceed 0.05%. If the water content exceeds allowable levels then: Determine how water is entering the unit and remedy the condition. Drain the unit and inspect for damage, repair if needed. ACE World Companies, Inc. ASM8 Installation & Maintenance Manual December Page 4 of 8 62

64 ASM8 Installation and Maintenance Manual Flush and re-fill the unit with the proper lubricant. Do not overfill the ASM8. Exceeding the recommended oil level could result in leakage, seal failure, hard-starts, and overheating. Maintenance Schedules The severity of the operating environment plays a large role in determining maintenance intervals of the ASM8. The following general maintenance schedule provides a minimum guideline if an existing, application-based maintenance schedule does not exist. During normal operation, the ASM8 can reach temperatures that can cause injury. Do not touch these surfaces when the unit is hot. Do not touch hot surfaces. After the First Week After the ASM8 has operated for one week: Check the installation for alignment and rigidity. Re-tighten any loose bolts to the proper tightening torque. Check the oil level. Visually check the ASM8. Correct any problems discovered. After the First Month After the first month of operating the ASM8: Drain and flush the unit with new oil of similar type and viscosity of the existing lubricant. Re-fill the ASM8 with the proper lubricant type and viscosity to the correct level. Visually inspect the ASM8. Correct any problems discovered. Dispose of used lubricants according to federal, state, and local rules and regulations. Each Month of Operation After each month of operating the ASM8: Check the oil level. Visually inspect the unit. Correct any problems discovered. Periodic Lubricant Change Over time and use, the lubricant will degrade and its load carrying capacity will diminish. Periodic lubricant changes must be performed to flush the ASM8 of contaminants and maintain the correct lubricant viscosity. The preferred method of determining lubricant change intervals is through periodic laboratory analysis. Your lubricant supplier can recommend a testing facility for lubricant analysis. If lubricant analysis is not performed, then change the lubricant per the following schedules: Petroleum based lubricants should be changed every 2,500 hours of use or every six (6) months, whichever occurs first. Synthetic based lubricants should be changed every 0,000 hours of use or every two (2) years, whichever comes first. During normal operation, the ASM8 can reach temperatures that can cause injury. Do not touch these surfaces when the unit is hot. Do not touch hot surfaces. ACE World Companies, Inc. ASM8 Installation & Maintenance Manual December Page 5 of 8 63

65 ASM8 Installation and Maintenance Manual Seasonal Temperature Affects Certain applications may experience seasonal temperature variations that require different lubricant viscosities at different times of the year. It is important to insure that the correct lubricant viscosity is used throughout the year. A lubricant with too heavy a viscosity may produce high starting loads and inadequate lubrication of highspeed bearings and gears. A lubricant with too light a viscosity may not provide adequate load capacity, resulting in unit overheating and pre-mature bearing and gear failures. Refer to tables 2 and 3 for recommended lubricant viscosities and products. Additional Information and Notes: Nameplate Information The following figure provides a convenient place to record the nameplate information from your AMS8. This information is important when identifying spare parts or requesting technical assistance. Fort Worth, TX USA UNIT TYPE: SERIAL NUM: LUBE: 750 RATIO ACE World Companies, Inc. ASM8 Installation & Maintenance Manual December Page 6 of 8 64

66 ASM8 Installation and Maintenance Manual Lubrication Tables and Figures Recommended ISO Viscosity Grade Ambient Temperature ( F) Petroleum Based Lubricants Synthetic Based Lubricants -40 to 5 Not Recommended 50 5 to to to 20 Not Recommended 320 Table 2 Recommended ISO Viscosity Grades Lubricant Product Name Manufacturer ISO Viscosity Grade Petroleum Based Synthetic Based 50 Mobilgear 629 () Mobilgear SHC 50 () Mobil 220 Mobilgear 630 () (2) Mobilgear SHC Not Recommended Mobilgear SHC Meropa 50 Pinnacle EP 50 () Texaco 220 Meropa 220 Pinnacle EP 220 () 320 Not Recommended Pinnacle EP Omala 50 Omala RL 50 Shell 220 Omala 220 Omala RL Not Recommended Omala RL 320 () Denotes Extreme Pressure Lubricant. EP Lubricants are preferred over non-ep lubricants. (2) Denotes ASM8 Standard Factory Petroleum Based Lubricant (3) Denotes ASM8 Standard Optional Factory Synthetic Based Lubricant Table 3 Recommended Lubricants Mounting Position Lubricant Volume, ounces M () 4 M2 32 M3 33 M4 32 M5 22 M6 22 () Denotes Factory Filled Lubricant Volume for Unspecified Mounting Positions Table 4 Lubricant Volumes at Various Mounting Positions () (3) Figure Lubricant Level and Drain Locations at Various Mounting Positions ACE World Companies, Inc. ASM8 Installation & Maintenance Manual December Page 7 of 8 65

67 ASM8 Installation and Maintenance Manual Long Term Storage If a unit is inactive or stored for long periods, then the unit must be prepared for long-term storage: Drain the lubricant and coat the inside with rust preventative oil that is soluble in lubricating oil. Completely seal the unit from the environment by removing any vented plugs or breathers and replacing them with the factory recommended drain plugs. Grease all seals with mineral based NLGI #2 grease. Apply a thin coat of rust preventative to the exposed metal surfaces of the housing and shafting. Every month, rotate all shafts at least one complete revolution to insure that the rust preventative coating covers all components. Inspect stored units every six months and re-apply rust preventative and grease as required. It is recommended to store the ASM8 indoors. Before returning the unit into operation: Flush the unit with new lubricant and fill to the proper level. Refer to tables 2 through 4 and figure. Wipe excessive grease and rustpreventative from the housing and shafting. Visually inspect the unit and check all bolts for proper tightening torque. Check for gear or bearing damage by rotating all the ASM8 shafting a minimum of one revolution. Factory Information The ASM8 is proudly manufactured and assembled in the USA by ACE World Companies, Inc. ACE World Companies, Inc Jacksboro Hwy Fort Worth, TX 7635 Tel: Fax: Here are additional products and services provided by ACE World Companies to help meet all your material handling needs: A complete line of built-up hoists up to 700 ton and 750 hp. Crane design and manufacturing. Rebuild and re-design of hoist and special application reducers. Custom gear reducer design and manufacturing capabilities. Complete electrical packages, including variable frequency control drives. Replacement top-running and underhung trolley/hoists. Standard and custom designed endtrucks. Special machinery projects. Repair, Assembly, and Disassembly Refer to the ASM8 Parts and Repair Manual for information regarding the repair, assembly, and disassembly of the ASM8. ACE World Companies, Inc. ASM8 Installation & Maintenance Manual December Page 8 of 8 66

68 0200 JACKSBORO I-IWY.,FORT WORTII,TEXAS 7635 PH: (87) FA.'X: (87) WEBSITE; IES.COM REG ISTERED ISO 900 COM I'ANY C

69 .. Vvhen moving the unit, care should be taken to protect external parts (fom breakage or damage due to accidental knocks or ralls. If the unu Is to be stored In a hostile atmosphere or for a long penoo of time (24 months), It IS importart 0 apply protective and walerproof'ing products to avoid deterioration of shan. and rubber parts. Belore starting up the unit, carry out the folowing checks: Check the data shown on the name plate of the reduction unn and/or the electric motor; Check for any ~aks of klbric.ant It possible, remove any traces of dirt from the r.hlft end from the arlli58 around the o~ seal. If the oil seal Is noc Immersed in the lubricant Inside the assembly during partlcularlv long storage periods (46 months) It Is recommended that II should be replaced as the rubber might stick to the shift Of even hive lost the elasticity It need. to work Example o f a pulley mounted eorr.ctly on the slow shaft o f. reduction unit, Particular care must be taken when instating drives, as this Is often the source of damage and down time, Careful choke of the type of dft.ie and mounting positjon can olten avoid the need fur ptltection of sensitive areas, partictjlarly underneath the unit from oi leaka, lloweyer limited they may be, The machine must be firmly rastened in place in order to prevent any vibrations.. 'M'Ienever pouibll, proted the reduction unit from direct SlJnllghl and bad weather, especially when. Is mounted on Its vertical axis. Make sure the air intake on the fan side Is unobstructed in order to ensure that the motor Is correctty ()()Oled. - In the case of temperatures of < os C Of > +-40 C, contact Tectonlcal Asshun::.. - If the motor Is 0 be started very onen under load, the use of a heat probe nserted Into the motor Is recommended. The various machine members (pulleys, gear wheels, couplings, etc.) must be mounted on the shans using 5pl!dal threaded holes Of other systems that ensure correct operation wilhoullisk of causing damage to the bearings or the external parts of the assemblies (rig.). Lubricate the surtac.. that come Into contad: in order to pntvent oxidation or seizure. Fig. Correct and Incorrect examples o f pulleys mounted on the main sha ft o f a reduction unit. Fig A[

70 I ~ COrTOCt and Incorrect Q)lamples of coupling connections. Ag. 3 A A Statt!" ~ UP' The unit should be started up gradually: do nol Immediately apply the maximum load the machine Is able 0 take ; look for and correct any malfunction that may be caused by Incorrect mounting. Running-ln Is not essential for the reduction unit to full properly since modem construction techniques for me gears and castings, the extreme cleanliness of the internal parts, and the excellent qualities of the lubricants used. enstjre lhat the Internal parts receive a high degree of protection even during the first moments. 'A),.),e) The pulley mua be mounted on the main shaft as close as possible to the shoulder so that is does not cause e)(cessive radial load on the bearvlgs (fig. 2).Great care must be laken when connecting the couplings to ensure thai they are well aligned, so as not to cause excessive radial load on Ihe bearings (lig.3).vyhen It Is applied, paint must never be used on rubber part8: oil seal, etc. II must never be applied to any breather noles In plugs if they are mounted on the unlun the case of assemblies with all plugs, remove the closed cap used for transpor and fit it with the breather plug that IS supplied w!ttlthe reduction unit.wlen the assembly is supplied without a motor, the following precautions must be followed In order to ensure that connections are properly made Mounting the motor on the pam as Ilange Check thai the tolerance of ttle motor shaft and the motor flange comply with at least one 'normal' class of quality. Carefully clean off any trace of dirt or paint from the shan, the centering diameter al')(l the faee of the Range. Carry out mounting operations making sure not to use folce. II this is not possible, cheek the tolerance of the motor key and ensure that it Is correctly fitted. Apply assembly grease to the shan In order to prevent o)lidallon or seizure caused by contact Good quality motors should be used In oroer to ensure that the unit wonts correctly, without vibrations or noise. Before mounting the unit on the machine, check that the principal shan of the reduction unit rotates In the right direction. USB the oii window, if present, 0 clleck Ihat th6/ubrlcanr reaches the corroct level required for fh9 mounllng pos/llon used. The high degree of finish of the internal parts ensures that Ihe unit wltl worl< correctly with only a minimum amount of servicing Generally speaking, the following rules should be followed: perlodlcalty Check that the exterior of the assembty Is clean, especially In the cooling Breas; periodically check to see If there are any leaks, especially in the areas around the oil seats. Assemblies that are lubricated for life and thus do not have any 0 plugs do not require any special maintel'lance except 85 staled l!lbove. For other assemblies, low maintenance Is required with an 0 change al 8/0,000 hours of use. The change of oil naturally depends on the type 0 environmenl and use to whleh the unit Is put. Apart from the normal maintenance rules given above, make sure the breather hole in the plug Is clean and. usl"9 the 0 window, periodically check thai there Is sufficient lubricant. Should it be necessary 0 top up with lubricant. use the same type that Is already In the reducer or one that is compatible with H. In case of doubtful Incompatibility between lubrleants. we recommend you empty out the oil from Ihe gellr'box completely lind, before refilling with new 0. wash o ut the unit to remove any residue. VIrtIen chan~ng the oil, fouow the previous Instructions. TrQu6 sl.qptln If any problems should arise when starting the unit or during its first lew hours of operation, contact Ihe after sales service unit of Molovario. The lable shows 8 series of problems with a description of possible remedies. It should be kept in mind however thl!lt the information given )s for reference only, as alilhe drtves manufactured by Motovario are thoroughly tested and checked before they leave the factory. Please nole that tampering with the assembly without prior authorization from Motovario Immedlatety Invalidates the warranty and ol'l:en makes H Impossible to ascertain the causes of a defect or malfunction. 69

71 it,,,u ill.$ii'~ otl n~ Troubleshooting PROBLEMS Tn. malor dofli no' "MI. CAUSES Prob/timl Ytttl pcmw supply. Defective motor. Wrong $b:e of m olol'. ACTION ( ACTION (2 Checll: power supply. Replac..~ motor. PROBLEMS No W emjlttent noise IlOIII b gctij/s. CAUSES Dirty mide the ghlbox. ACTION (J. No practical pmthm If \tia noim II.. no ai'fict 00 Ihi appticatbn ACTION (2) ReMn the assembly 0 Moovarlo illhera Is sigrmlcant noise when laaded. Cutrellf.~ by the molof ~ Qmtfer thmj Ihown on!he del,pia,.. WfOrG $lie 0 motor Rep/ilaC'4he.~ctrie Check the 'pplieetion. I motor and, If nec.,sary, tnii ~bn ri. No" {Whne} 'rom filil.~ ' T~IHe 0/ IN """... ~~,. W_ I I R"'~"'."", II I mofi)( houdg ;. w..y.. of molo.. lneon'ed Chedc: M.pplicatlon. motor and, If n.clsury, EifKIric mofol" WnI8.t. high. mo&.w'iting of motor ti'li' ~ 00. Wr0"G sa. 0 ~n Corrett M woridrg unit. Mounting position conditions, molwlting position.rdior lubricant cfmotol... r~tunt rjfttt. ntducljon unilllori$ing does not comply with!he ~ the applicatiofl. III Wlyh/gh. order. Incorrect mounlir;l Bearing. Ioco~ Gea~ YIIh mhhl Chick c:orract quanti!y ofl Rel.an the assembly to drive.~. arrors. tnslll'rlcitnl. tubrlcant. MoIovario lubricant. Ueasurement of the Isseml!ty couping. Check geornatrk tola,.nee of n.nga on alaetric motor. Chaek I RepIIe. al&ctric motr:lr. tolafanee Ind gaomelry of kay on mot«shaft. 70 IfICOO'Kt rohttion 5p&ed of rf~ m.n redulcef / 'heft. Inc:orrtoa reduction ratio. I Check r.ductlon rallo, I Replace I$dUctlon unm Incorrect poi.nty of motor. Check polarity of molol". Illtilor electoc motor. Oefed'iw 0 Mal. OJ seal Replau the oil seal. IRepIiJ(:e Ina P'rt or relwn' Oil_Ilk from 0'.... Idamaged duflng snpmlmlt. R~r motor, haft (If lhe nsembiy to o.tectiw motor shaft. ponlbtl). MotOY.no. 0iIMk h"om joint Flat gasket or O-ring Replace damaged gasbtl Retum the.,sembfy to dam~. Of O-ring. Motowrio The '""".tj." rot./m Incorr.a connection 0 thii SWilP two pha_ of the ft.wrong_y. eiktric motof motor supply RttWTI the assembly 0. No practical ptotmm if.e~ no/ee from Delts In It- gear..neels. the noise!las no effect on Motovario II' there b ge&/s. It- application. signi!learol non. when

72 ~ ';l;{luyal;<ippj[c'a\i.<lls The perlon'n.nce given In the c.labp correspond to molnling position B3 or slmnar, Ie. when the flrsl.lage & no( entifety Immersed in oil. For oint mounting positions ano'er particular II'Iput speeds., relet to the "bias that highlight different critie. situations for each size of reduction unit. It Is.Iso necessary to taka due conlidellition of aocl careh..dty a'$ii$$ Iha following applications by calling ~ Tectmlc. Service: As. speed increasing. Use in 5etvices thiiil could be haurdou; lor p!topie if the reduction unit fers. Appi'Cltions with especially high inertia Use as I HIting winch. Applications with high dynamic str.in on the case of the raductioounit. In places wlt T" under.s'c or OYer 4O"C. Use in chemically aggressive environments. Use In It salty environment. Montlrog po»itioros '0 enyi&aged in the catalogue, Use in flidioadiye envirorvnents, Use In envfrofvenls pressu~ othqr th4n atmospheric pressue Avoid.pplieltions where even partial Inwnersion of the r.duetion unit Is required. The m-xmum torque { that the gear raducef Colll support must not exceed two limes \he oominal torque (f...'),talld In the performance tables. (") Intend&d lor momen3ry overloads du. to starting al ful load, br.klog, st\oeks Of othlf ClIU5eS, particularly those thai are dynamic B OBO '2000 < n < B B B VS V6 B B B B B n > 3000 B B B A A... L: B B B B B 7 A Application not recommended B Check the applicallon and/or call our technical sefvice

73 i I 72

74 ~,l.u6,~c;!i6n (BilS- S) In eases of ambient tempera\jres not enllisagod 0!he lable, call our Technical Service. In the ease of temperatures undel 30 C or over SO"C it is necessary to use oil seals with special properties. For operating ranges with temperatures under O' C it is r.ecessary to consider the following: I-The motors need to be $llitable for opernlioo at \e envisaged ambient temperature. 2-Tile power of the ejectric motof I&EIds to be adequate for exceedlr\g the higher starting torques required. 3-0 the case of reductioo units with a cast-iroo case, pay attentielr'0 Impact loads slnoe cast iroo may have probloltl$ of ragility at temperahlrlil$ uoder -5' C. 4-During!he early stages of service, problems of lublicatioo may arise due 0 the high level of viscosay taken 00 by the oil and so itis wise 0 have II few minutes of rotalkm under roo load. The 0 needs to be changed after approximately 0,000 hours. This period depends on the type 0 service alld the erwirorlmerot where lhe reduction urlit worb. For units supplied withoy! 0 plugs. lubricatioo Is permal'lell"it aod so they l6ed roo solvicl0g. CD AlIenz~ne: riduttolll prti/o dl lu brwcante,nem plnl & MIlk> Ffimo deu'liwglmanlo I T'C ISOVG. ""P SHELL ESSO MOBIL CASTROL -, BP Mjnetalo~ I (-5) -;- (+40 (-5) + (+25) ISO VG220 ISO VG l 50 BLASIA BLASIA 220 '"0 OMALA OMALA 0L220 OH.. SO SPARTAN SPARTAN EP220 EPISO MOBILGEAR MOBJLGEAR ALPHA MAX, ALPI"A MAX ENERGOL ENERGOL GR-XP220 I GR XP50 I I riduttorl di m(tdiajgrossa taglla vet!l0oo for nm prm dl olio e compieti del tappi oecossarl a gal'l'lntlr. tutte Ie pos\z:or\i di pillzzilmentoj sudetti ridllttori vengol"lo contraddislinll dal!"adollcaziom della relalna Arlen tlol'l: """rbox un~ v.itf>o u t lubrlca n~ ~ ~ UplQ the level beklre stamng, Acht""t;. Gelriete ome ScIlmlerstoJ'l', bolte WI Inbelne a ~me folen. o AIIan tloo,groupil SlIn.. lublffiant oempllr.u niveilu!\'wi'll Ie Alen~6n: g-upo sin I\jbtical'lte, lienlfhrsl. ej nm)! enlesde la puesta an /ll3rl:~a. I I B... "00 lubrificato ~... ~,- T"C I (-5)+(...0) I (.5)+(+25) ISOVG220 ISOVG00 --~ --ISOva... III B ' V. V6 C V. V6 ' "B ca &-87 V. V6 M2 0, , Quantity of 0 In I~res 2" 3 2,6 3,9 2,8 AS2 AS3 An All 0,<5 0,45+(0,3),.. (C, 3) AS2 AS> A72 A73 0,3 0,3 + (O,3) 0,8 0,8" (0.3) 03 "3 53 3,7 '" 6,S 20 4,6 8,2 " ,2 22 " 32 4,2 6,8 20 6,8 '" " " 73

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86 WorldCompan 0200 JACKSBORO HWY.,FORT WORTH,TEXAS 7635 PH: (87) FAX: (87) WEBSITE: REGISTERED ISO 900 COMPANY 85 CS - IS - S

87 When moving the unit, care should be taken to protect external parts from breakage or damage due to accidental knocks or falls. If the unit is to be stored in a hostile atmosphere or for a long period of time (2/4 months), it is important to apply protective and waterproofing products to avoid deterioration of shafts and rubber parts. Before starting up the unit, carry out the following checks: Check the data shown on the name plate of the reduction unit and/or the electric motor; Check for any leaks of lubricant If possible, remove any traces of dirt from the shaft and from the areas around the oil seal. If the oil seal is not immersed in the lubricant inside the assembly during particularly long storage periods (4/6 months) it is recommended that it should be replaced as the rubber might stick to the shaft or even have lost the elasticity it needs to work. Example of a pulley mounted correctly on the slow shaft of a reduction unit, Particular care must be taken when installing drives, as this is often the source of damage and down time. Careful choice of the type of drive and mounting position can often avoid the need for protection of sensitive areas, particularly underneath the unit from oil leaks, however limited they may be. - The machine must be firmly fastened in place in order to prevent any vibrations. - Whenever possible, protect the reduction unit from direct sunlight and bad weather, especially when it is mounted on its vertical axis. - Make sure the air intake on the fan side is unobstructed in order to ensure that the motor is correctly cooled. - In the case of temperatures of < -5 DC or > +40 DC, contact Technical Assistance. - If the motor is to be started very often under load, the use of a heat probe inserted into the motor is recommended. - The various machine members (pulleys, gear wheels, couplings, etc.) must be mounted on the shafts using special threaded holes or other systems that ensure correct operation without risk of causing damage to the bearings or the external parts of the assemblies (fig. ). - Lubricate the surfaces that come into contact in order to prevent oxidation or seizure. Fig. Correct and incorrect examples of pulleys mounted on the main shaft of a reduction unit. Fig B

88 .. Correct and Incorrect examples of coupling connections. Fig. 3 A A The unit should be started up gradually: do not immediately apply the maximum load the machine is able to take ; look for and correct any malfunction that may be caused by incorrect mounting.. Running-in is not essential for the reduction unit to run properly since modem construction techniques for the gears and castings, the extreme cleanliness of the internal parts, and the excellent qualities of the lubricants used, ensure that the internal parts receive a high degree of protection even during the first moments. (A) (8) (e) The pulley must be mounted on the main shaft as close as possible to the shoulder so that is does not cause excessive radial load on the bearings (fig. 2}.Great care must be taken when connecting the couplings to ensure that they are well aligned, so as not to cause excessive radial load on the bearings (fig.3}.when it is applied, paint must never be used on rubber parts: oil seal, etc. It must never be applied to any breather holes in plugs if they are mounted on the uniun the case of assemblies with oil plugs, remove the closed cap used for transport and fit it with the breather plug that is supplied with the reduction unit.when the assembly is supplied without a motor, the following precautions must be followed in order to ensure that connections are properly made Mounting the motor on the pam 85 flange Check tliat the tolerance of the motor shaft and the motor flange comply with at least one 'normal' class of quality. Carefully clean off any trace of dirt or paint from the shaft, the centering diameter and the face of the flange. Carry out mounting operations making sure not to use force. If this is not possible, check the tolerance of the motor key and ensure that it is correctly fitted. Apply assembly grease to the shaft in order to prevent oxidation or seizure caused by contact. Good quality motors should be used in order to ensure that the unit works correctly, without vibrations or. noise. Before mounting the unit on the machine, check that the principal shaft of the reduction unit rotates in the right direction. Use the oil window, if present, to check that the lubricant reaches the correct level required for the mounting position used. The high degree of finish of the internal parts ensures that the unit will work correctly with only a minimum amount of servicing Generally speaking, the following rules should be followed: periodically check that the exterior of the assembly is clean, especially in the cooling areas; periodically check to see if there are any leaks, especially in the areas around the oil seals. Assemblies that are lubricated for life and thus do not have any oil plugs do not require any special maintenance except as stated above. For other assemblies, low maintenance is required with an oil change at 8/0,000 hours of use. The change of oil naturally depends on the type of environment and use to which the unit is put. Apart from the normal maintenance rules given above, make sure the breather hole in tile plug is clean and, using the oil window, periodically check that there is sufficient lubricant. Should it be necessary to top up with lubricant, use the same type that is already in the reducer or one that is compatible with it. In case of doubtful incompatibility between lubricants, we recommend you empty out the oil from the gearbox completely and, before refilling with new oil, wash out the unit to remove any residue. When changing the oil, follow the previous instructions. If any problems should arise when starting the unit or during its first few hours of operation, contact the after sales service unit of Motovario. The table shows a series of problems with a description of possible remedies. It should be kept in mind however that the information given is for reference only, as all the drives manufactured by Motovario are thoroughly tested and checked before they leave the factory. Please note that tampering with the assembly without prior authorization from Motovario immediately invalidates the warranty and often makes it impossible to ascertain the causes of a defect or malfunction. 87